2.5DCI Engine Mechanical
2.5DCI Engine Mechanical
2.5DCI Engine Mechanical
J496030
Remove
Install
5. For vehicles with F4R 820 engine, program pedal position sensor using Tech 2.
Page 1 of 1
J815500
Remove
Install
J470435
Measure
3. Install suitable magnetic base (commercially available) and Dial Gauge MKM-571-B to turbocharger
• Position probe of dial gauge in contact with control actuator rod (arrowed)
• With probe of dial gauge on control actuator rod, set dial gauge reading to 0 (zero)
5. Remove dial gauge and Pressure and Vacuum Pump MKM-667 from turbocharger
6. Remove turbocharger from soft-jawed vice
7. Install turbocharger to vehicle – see operation “Turbocharger, Replace”
Page 1 of 12
J705100
Remove
1 2
3
S 0012762
7. Lower vehicle
8. Secure radiator assembly to front crossmember
Note: To allow access to the alternator.
• Use 2x cable tie
9. Remove pulley from power steering pump
• Remove 3x bolt
10. Release power steering feed hose from auxiliary support bracket, then
move to one side
• Pull off
Page 3 of 12
S 0012764
11. Remove bracket (1) from auxiliary support bracket and EGR valve
housing
• Remove 2x bolt (2)
• Release 2x harness from bracket
– Release 2x clip (3)
2
3 S 0012765
12. Release power steering pump from engine, then move to one side
• Remove 3x bolt
Page 4 of 12
S 0012766
Install
S 0012766
20. Install bracket (1) to auxiliary support bracket and EGR valve housing
• Install 2x bolt (2) 15 Nm
• Secure 2x harness to bracket
– Secure 2x clip (3)
Page 9 of 12
3 S 0012765
S 0012764
1 2
3
S 0012762
1 2
3
S 0012762
29. Install upper front panel – see operation “Upper Front Panel, Remove and Install or Replace”
30. Connect battery negative lead
31. Program all volatile memories
Page 1 of 8
J705100
Remove
S 0012771
5. Lower vehicle
6. Secure radiator assembly to front crossmember
Note: To allow access to the alternator.
• Use 2x cable tie
7. Remove bracket (1) from auxiliary support bracket and EGR valve
housing
• Remove 2x bolt (2)
• Release 2x harness from bracket
– Release 2x clip (3)
Page 3 of 8
2
1
S 0012772
S 0012773
S 0012779
Install
S 0012779
S 0012773
14. Install bracket (1) to auxiliary support bracket and EGR valve housing
• Install 2x bolt (2) 15 Nm
• Secure 2x harness to bracket
– Secure 2x clip (3) 2
1
S 0012772
S 0012771
18. Install upper front panel – see operation “Upper Front Panel, Remove and Install or Replace”
19. Connect battery negative lead
20. Program all volatile memories
Page 1 of 10
J462060
Remove
Install
6. Install Sleeve KM-6424-1 (2) over stud (1) onto end of camshaft
7. Locate new camshaft oil seal (3) on sleeve (2)
Page 3 of 10
8. Locate sleeve (2) of Installer KM-6300 against camshaft oil seal (3)
9. Loosely install nut (1) of Installer KM-6300 against sleeve (2)
Remove
Install
22. Install Sleeve KM-6424-1 (2) over stud (1) onto end of intake camshaft
23. Locate new camshaft oil seal (3) on sleeve (2)
24. Locate sleeve (2) of Installer KM-6300 against camshaft oil seal (3)
25. Loosely install nut (1) of Installer KM-6300 against sleeve (2)
Page 8 of 10
J491840
Remove
Install
Camshafts, Replace
J314570
Remove
9. Install Positioning Pin KM-6203 (arrowed), through oil filter housing into
crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
Page 3 of 14
10. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
11. Lower vehicle
12. Remove support bracket (1) from engine
• Remove 4x bolt (2), nut (3)
Page 4 of 14
15. Install Locking/Measurement Tool KM-6205 and Locking Tool KM-6204 to 2x camshaft
• Install 2x bolt
16. Remove timing belt – see operation “Timing Belt, Replace”
• G9U 630
• G9U 730
17. Remove 2x hub for 2x camshaft pulley from engine
Note: 2x technician required.
• Remove 2x bolt
20. Remove Locking/Measurement Tool KM-6205 and Locking Tool KM-6204 from 2x camshaft
• Remove 2x bolt
Important: Each camshaft cap must be marked to identify its position for
subsequent assembly.
21. Mark 12x camshaft cap as shown
Install
S 0017908
Important: Apply clean engine oil to bearing journals of cylinder head and
camshaft.
25. Install new exhaust camshaft to cylinder head
• Position exhaust camshaft in cylinder head
• Loosely assemble 6x exhaust camshaft cap (1, 2, 3, 4, 5, 6) to
cylinder head
• Secure 2x exhaust camshaft cap (1, 6) 13 Nm
• Secure 4x exhaust camshaft cap (2, 3, 4, 5) 10 Nm
Important: Apply clean engine oil to bearing journals of cylinder head and
camshaft.
26. Install new intake camshaft to cylinder head
• Position intake camshaft in cylinder head
• Loosely assemble 6x intake camshaft cap (7, 8, 9, 10, 11, 12) to
cylinder head
• Secure 2x intake camshaft cap (7, 12) 13 Nm
• Secure 4x intake camshaft cap (8, 9, 10, 11) 10 Nm
Page 9 of 14
27. Install 2x new oil seal to 2x camshaft – see operation “Camshaft Oil Seal, Replace"
Important: Ensure that the flat surfaces (arrowed) on the end of the rocker
shafts are positioned to the timing side of the cylinder head.
28. Install exhaust rocker shaft to cylinder head
• Install 6x bolt; do not tighten at this stage
29. Install intake rocker shaft to cylinder head
• Install 6x bolt; do not tighten at this stage
30. Secure 12x bolt 13 Nm in sequence shown
Page 10 of 14
32. Install Locking/Measurement Tool KM-6205 and Locking Tool KM-6204 to 2x camshaft
• Install 2x bolt
33. Install 2x camshaft pulley hub to 2x camshaft
• Install 2x bolt; do not tighten at this stage
34. Secure 2x camshaft pulley hub to 2x camshaft
• Secure 2x bolt 44 Nm
Note: 2x technician required.
35. Remove Locking/Measurement Tool KM-6205 and Locking Tool KM-6204 from 2x camshaft
• Remove 2x bolt
36. Install new timing belt – see operation “Timing Belt, Replace”
• G9U 630
• G9U 730
37. Install cylinder head cover – see operation “Cylinder Head Cover, Replace"
• G9U 630
• G9U 730
45. Remove Engine Support KM-6210-A – see operation “Engine Support KM-6210-A, Install and Remove”
46. Install right splash panel
• Secure washer hose to 2x clip
• Install 2x bolt 8 Nm , screw 6 Nm
J741100
Remove
S 0012741
2. Raise vehicle
3. Remove engine and transmission undershield from vehicle
• Remove 8x bolt
S 0013245
Install
S 0013245
S 0012741
Page 1 of 2
Check alternator
The following table provides an overview of the alternator check procedure.
Battery check
Alternator check
J491040
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
2. Disconnect battery negative lead
3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
S 0012752
1
1
S 0012753
8. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
1
2
3
S 0012861
9. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
Page 4 of 34
1 2
S 0012918
10. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Release clip (2)
• Remove bolt (3) 2
1 3
S 0012860
Page 5 of 34
1 2
3 S 0012862
S 0012741
2 S 0012714
S 0012865
18. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
S 0013065
S 0013066
S 0013067
S 0012992
S 0013069
26. Remove oil level dipstick (3) from guide tube (4)
27. Release harness from oil level dipstick guide tube
• Release from clip (1)
28. Remove upper section of guide tube (4) from engine
• Remove bolt (2)
• Release 2x clip
• Remove O ring
• Install new blanking plug
Page 13 of 34
1 2 3
S 0013070
30. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side
• Release from clip on engine lifting eye
• Release 2x integral clip (2)
• Install 2x new blanking plug
Page 14 of 34
2 S 0012995
33. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
34. Disconnect high pressure pipe (2) from high pressure pump
• Release pipe union (3)
– Use Pipe Spanner KM-812 ; counterhold nut on high pressure
pump using suitable spanner 1 2
• Install 2x new blanking plug
35. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Release integral clip
• Install 2x new blanking plug
3 S 0013000
38. Remove high pressure pipe from common rail and cylinder head cover
• Release pipe union (1)
– Use Pipe Spanner KM-812
Install
41. Install 4x high pressure pipe (1) to common rail and 4x fuel injector; do
not tighten at this stage
• Remove 16x blanking plug
42. Secure 4x high pressure pipe to common rail
• Secure 4x pipe union 22 Nm
– Use Pipe Spanner KM-812
Page 18 of 34
S 0009855
47. Install high pressure pipe (1) to common rail; do not tighten at this stage
• Remove 2x blanking plug
Page 20 of 34
52. Install new fuel leak-off pipe with fuel temperature sensor to high pressure pump
• Remove 2x blanking plug
• Secure integral clip
53. Connect fuel leak-off pipe to common rail
• Remove 2x blanking plug
• Secure 2x integral clip
2 S 0012995
58. Install upper section of guide tube (4) for oil level dipstick to lower
section and engine
• Remove blanking plug
• Install new O ring 1 2 3
• Push into lower section of guide tube to secure to 2x clip
• Install bolt (2) 6 Nm
59. Secure harness to guide tube for oil level dipstick
• Secure clip (1)
60. Install oil level dipstick to guide tube 4
• Secure to clip (3)
S 0013070
S 0013069
S 0012992
S 0013067
S 0013066
S 0013065
68. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
Page 27 of 34
S 0013060
S 0012865
2 S 0012714
S 0012741
1 2
3 S 0012862
74. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
75. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
1
2
3
S 0012861
76. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2)
Page 32 of 34
1 3
S 0012860
77. Secure coolant preheater harness (1) (if installed) to air cleaner support
frame (3)
• Secure clip (2)
1 2
S 0012918
1
1
S 0012753
79. Install air intake duct (1) to air cleaner (2) and vehicle body
• Secure 2x clip
S 0012752
2
1
3
S 0012749
1 2
S 0012751
Compression, Check
J451800
Remove
2. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
Page 2 of 12
1 2
S 0012751
S 0012749
5. Remove air intake duct (1) from air cleaner assembly (2) and front panel
• Release 2x clip
Page 3 of 12
S 0012752
1
1
S 0012753
7. Release harness (1) for mass air flow meter from support frame (2)
• Release clip (3)
Page 4 of 12
1
2
3
S 0012861
8. Release harness for coolant heater assembly (if installed) from support
frame
• Release clip (2)
9. Release bracket with coolant heater assembly (1) (if installed) from
2
support frame
• Remove bolt (3)
1 3
S 0012860
Page 5 of 12
1 2
3 S 0012862
Measure
13. Install Compression Test Adapter KM-6211 (1) to glow plug hole of No.
1 cylinder 11 Nm
Install
1 2
3 S 0012862
24. Secure bracket with coolant heater assembly (1) (if installed) to support
frame
• Install bolt (3)
25. Secure harness for coolant heater assembly (if installed) to support
2
frame
• Secure clip (2)
1 3
S 0012860
26. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
Page 10 of 12
1
2
3
S 0012861
1
1
S 0012753
28. Install air intake duct (1) to air cleaner assembly (2) and front panel
• Secure 2x clip
Page 11 of 12
S 0012752
S 0012749
1 2
S 0012751
Remove
10. Rotate crankshaft until No. 1 and No. 4 con-rod positioned at bottom
dead centre
11. Apply identification and alignment marking to 4x con-rod cap
Page 4 of 12
Install
Important: Tighten 23x oil pan bolt in stage and sequence shown.
29. Tighten 23x oil pan bolt
• Tighten 23x oil pan bolt 5 Nm in sequence shown
• Tighten 23x oil pan bolt 9 Nm in sequence shown
Page 10 of 12
37. For G9U730 engine, remove engine immobiliser/instrument panel fuse from interior fuse box
• Remove left ashtray housing from instrument panel
– Release 4x clip
Remove
Install
J609100
Remove
9. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
10. Connect suitable hose to radiator drain plug
11. Lower vehicle
Page 3 of 22
Important: Observe the relevant environmental regulations when disposing of used coolant.
12. Drain cooling system
• Place collecting container below
• Open radiator drain plug
• Allow coolant to drain into collecting container
13. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
14. Release reservoir for power steering fluid from upper front panel, then
move to one side
Note: To prevent fluid loss ensure reservoir remains in vertical
position.
• Release clip, then slide off
17. Disconnect hose (2) from mass air flow meter (1)
• Release clip
18. Disconnect harness connector (3) from mass air flow meter
Page 5 of 22
19. Release air intake duct (1) from air cleaner assembly (2)
• Release 2x clip
24. Remove bracket with upper engine stabiliser from engine compartment
• Remove 4x bolt (2), nut (1)
Page 7 of 22
25. Remove bracket for intercooler hose assembly from upper cover for timing belt
• Remove 2x bolt
Install
42. Install bracket for intercooler hose assembly to upper cover for timing belt
• Install 2x bolt 8 Nm
Important: Observe the relevant environmental regulations when disposing of used engine oil.
48. Drain engine oil
• Place collecting container below
• Remove drain plug
• Remove sealing washer
49. Install drain plug 25 Nm
• Install new sealing washer
67. Secure reservoir for power steering fluid to upper front panel
• Slide on to secure clip
68. Connect battery negative lead
69. Program all volatile memories
70. Remove oil filler cap
71. Fill engine oil to correct level
• Install oil filler cap
• Start engine to prime oil filter
• Stop engine
72. Bleed cooling system – see operation “Cooling System, Drain and Refill”
73. Check and adjust oil level if necessary
Note: Wait until the engine oil level has settled to correct level.
74. Raise vehicle
75. Install radiator splash shield
• Install 3x bolt (1, 2) 8 Nm
Page 21 of 22
4. Raise vehicle
8. Lower vehicle
Remove
8. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
11. Remove air intake duct (1) from air cleaner assembly (2)
• Release 2x clip
Page 3 of 8
Install
24. Install air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
Page 6 of 8
Disassemble
Assemble
7. Lubricate crankshaft and shell bearings with engine oil and assemble
8. Torque tighten crankshaft cap bolts, refer to “Technical Data"
Important: Identify each connecting rod and bearing cap prior to removal to ensure correct installation
6. Remove 4x connecting rod bearing cap and 4x bearing shell from crankshaft
• Remove 8x bolt
Important: To maintain integrity of Plastigage thread, do not allow crankshaft to rotate when installing or removing any connecting rod
bearing cap
8. Install 4x connecting rod bearing cap and 4x bearing shell in original position
• Install 8x original bolt ( 25 Nm + 55° ± 6° )
9. Remove 4x connecting rod bearing cap and 4x bearing shell from crankshaft
• Remove 8x bolt
10.
Measure compressed width of Plastigage thread with calibrated scale
and determine crankshaft clearance of each connecting rod journal, see
"Technical Data". If necessary, measure diameter of each crankshaft
connecting rod journal. Replace connecting rod bearing shells if
Page 4 of 4
J794400
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
3. Disconnect harness connector (1) from crankshaft inductive pulse pick-
up
4. Release support bracket (2) from cylinder block
• Remove bolt (3)
Install
J463510
Remove
1. Remove crankshaft pulley – see operation “Crankshaft Pulley, Ribbed V-belt, Replace"
2. Remove crankshaft oil seal (1) from timing gear cover
Install
4. Partially install new crankshaft oil seal (2), located on Sleeve KM-6424-3
(1), into timing gear cover
7. Install crankshaft pulley – see operation “Crankshaft Pulley, Ribbed V-belt, Replace"
J455010
Remove
1. Remove clutch assembly from flywheel – see operation “Clutch Assembly, Replace”
• G9U 630, G9U 730 without self-adjusting clutch
• G9U 730 with self-adjusting clutch
• M9R 630, M9R 692, M9R 780, M9R 782, M9R 784, M9R 786, M9R 788
Install
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
Install
Crankshaft, Replace
J455000
Remove
Important: “Piston Protrusion, Check” is required after replacement of the following components: con-rods, crankshaft and cylinder block
– see operation “Piston Protrusion, Check”
1. Remove engine and transmission from vehicle – see operation “Engine with Transmission, Remove and Install”
Important: Observe the relevant environmental regulations when disposing
of used lubricants.
2. Disconnect feed hose (1) from power steering pump
• Place collecting container below
• Release clip
• Install 2x new blanking plug
• Remove O ring
• Install 2x new blanking plug
5. Remove power steering pipe assembly with fluid reservoir from engine and transmission assembly
Page 2 of 103
• Remove 4x bolt
6. Remove bracket (2), left side, from primary catalytic converter and
engine
• Remove 3x bolt (1)
• Release vacuum hose from clip on bracket
7. Remove bracket (3), right side, from primary catalytic converter and
engine
• Remove 4x bolt (4)
S 0012886
2
1
S 0012890
S 0012891
13. Remove coolant pipe (1) from coolant pump and thermostat housing
• Place collecting container below
• Remove bolt (2)
• Pull out coolant pipe
• Remove 2x O ring
• Install 2x new blanking plug
Page 5 of 103
15. Remove bracket from auxiliary support bracket and exhaust gas
recirculation (EGR) valve housing
• Remove 2x bolt (2)
• Release 2x harness from bracket
– Release 2x clip (1)
Page 6 of 103
2 S 0009574
16. Remove EGR cooler from intake manifold and EGR valve housing
• Remove 7x bolt (1), gasket
S 0016494
17. Remove EGR valve housing (2) with support bracket from engine
• Release clip (1)
• Remove 2x bolt (3)
Page 7 of 103
1 2
S 0013423
18. Remove upper section of guide tube for oil level dipstick from lower section
• Remove bolt
• Pull guide tube upwards, then release 2x clip
• Remove O ring
19. Remove lower section of guide tube for oil level dipstick from engine
• Remove bolt
• Withdraw lower section
• Install new blanking plug to engine
• Remove O ring
S 0012968
21. Remove 2x coolant hose from oil cooler and thermostat housing
• Place collecting container below
• Release 4x clip
• Install 4x new blanking plug
S 0016497
36. Remove air conditioning compressor (2) (if installed) from auxiliary
support bracket
• Remove 3x bolt (1)
Page 16 of 103
37. Remove timing belt from engine – see operation “Timing Belt, Replace”
38. Remove Positioning Pin KM-6203 (arrowed) from oil filter housing
S 0012717
43. Remove nut (1) from gear for high pressure pump
Page 19 of 103
49. If installing new high pressure pump gear – see operation “High
Pressure Pump Gear, Replace (All G9 Engines)” for timing gear
compensation
51. Remove intermediate gear (1), shaft (2) and washer (3) from engine
• Pull out
52. If installing new intermediate gear – see operation “Intermediate Timing
Gear, Replace (All G9 Engines)” for timing gear compensation
Page 23 of 103
54. Remove secondary intermediate shaft (1) and washer (2) from engine
• Pull out
Page 24 of 103
59. Disconnect fuel leak-off pipe (1) from high pressure pump
• Release integral clip
60. Remove fuel leak-off pipe with fuel temperature sensor from engine
• Release 3x clip
79. Remove oil filter and cooler housing (1) from cylinder block
• Place collecting container below
• Remove 3x bolt (2), gasket
Page 33 of 103
S 0016496
82. Remove drive chain (1) with gear and oil deflector (2) from crankshaft
(3)
• Slide off
Page 34 of 103
90. Remove 8x bearing (1) from 4x con-rod and 4x con-rod end cap
Note: Piston shown removed for clarity.
• Push out, using suitable tool
• Clean mating surfaces
Page 37 of 103
Install
Important: Ensure oil ports (2) in cylinder block and oil ports in new
grooved bearing (1) align. Failure to ensure correct alignment of oil ports will
result in engine failure.
91. Install 5x new grooved bearing to cylinder block
• Clean mating surfaces
• Apply clean engine oil to contact surfaces
• Push fit
Important: 23x original crankcase bolt must be replaced with 23x new bolt
after following procedure.
95. Install crankcase to cylinder block
• Clean all mating surfaces
• Install 10x original bolt 20 Nm in sequence shown
• Secure 10x bolt 150° ± 10° in sequence shown
Page 39 of 103
96. Measure crankshaft axial play – see operation “Crankshaft Axial Play,
Check”
• Check crankshaft for free rotation
– Adjust thrust washer size until correct axial clearance attained
98. Install 8x new bearing (1) to 4x con-rod and 4x con-rod end cap
Note: Piston shown removed for clarity.
• Clean mating surfaces
• Push fit
– Apply clean engine oil to contact surfaces
Page 40 of 103
S 0017910
113. Remove oil filter and cooler housing from soft jawed vice
114. Install oil filter and cooler housing (1) to cylinder block
• Clean mating surface of cylinder block 1
• Install new gasket
• Install 3x bolt (2) 25 Nm
S 0016496
115. Remove 4x high pressure pipe (1) from 4x fuel injector and common
rail
• Release 8x pipe union
– Use Pipe Spanner KM-812 ; counterhold nut on fuel injector
using suitable spanner
• Install 16x new blanking plug
127. Remove fuel rail protector (1) and gasket from cylinder head
• Remove 2x bolt
• Release grommet (2) from breather pipe connection
1 S 0013075
140. Install drive chain (1) with gear and oil deflector (2) to crankshaft (3)
• Push fit
Page 51 of 103
1 2
3 4
S 0016510
155. Install Positioning Pin KM-6203 (arrowed) through oil filter housing
into crankshaft
• Rotate engine clockwise, until positioning pin engages in
crankshaft to position No. 1 cylinder at top dead centre on
compression stroke
Page 57 of 103
S 0012717
157. Install Flywheel Positioning Tool KM-6403 (1) to cylinder block and
flywheel
• Push fit
– Position flywheel as necessary to ensure full location of tool
Page 58 of 103
159. Remove Flywheel Positioning Tool KM-6403 (1) from cylinder block
and flywheel
• Pull out
S 0012717
Important: Side (A) must be installed facing clutch pressure plate end.
162. Install clutch plate with Alignment Tool KM-6165 to flywheel
Page 60 of 103
S 0017939
S 0012717
168. Remove Positioning Pin KM-6203 (arrowed) from oil filter housing
Page 62 of 103
S 0012717
Important: Install 10x new cylinder head bolts. Do not lubricate cylinder
head bolts.
172. Install cylinder head to cylinder block
Note: 2x technician are required.
Note: Do not re-tighten cylinder head bolts after carrying out the
following procedure.
• Install 10x cylinder head bolt 30 Nm in sequence shown
• Check torque of 10x cylinder head bolt is 30 Nm in sequence
shown
• Secure 10x cylinder head bolt 300° ± 6° in sequence shown
Important: Ensure that the flat surfaces (arrowed) on the end of the rocker
shafts are positioned to the timing side of the cylinder head.
173. Install exhaust rocker shaft to cylinder head
Note: The exhaust camshaft pulley and both flanges are shown
removed for clarity.
• Install 6x bolt; do not tighten at this stage
174. Install intake rocker shaft to cylinder head
• Install 6x bolt; do not tighten at this stage
175. Secure 12x bolt 13 Nm in sequence shown
Page 64 of 103
178. Install 2x new rubber gasket, 7x new seal to cylinder head cover
• Clean all mating surfaces of cylinder head cover
187. Install fuel rail protector (1) and gasket to cylinder head
• Clean mating surfaces, then apply suitable sealant – see
“Sealants, Lubricants and Locking Compounds”
• Position drain hose to rear of engine
• Install 2x bolt; do not tighten at this stage
• Secure grommet (2) to breather pipe connection
Page 70 of 103
S 0013077
202. Install 4x high pressure pipe (1) to common rail and 4x fuel injector; do
not tighten at this stage
• Remove 16x blanking plug
S 0013082
215. Install new fuel leak-off pipe (1) with fuel temperature sensor to high
pressure pump
• Remove 2x blanking plug
• Secure integral clip
221. Install intermediate shaft and secondary intermediate shaft (2) with 2x
washer (1) to engine
• Ensure location pin of each intermediate shaft engages fully into
slot, then install 2x washer
• Push fit
Page 80 of 103
S 0012717
Important: Marking “2” on gear for high pressure pump must align with
marking “3” on timing case. This action is necessary to correctly align gear
for high pressure pump and camshaft position sensor for engine timing.
228. Install gear to high pressure pump
• Install nut (1) 90 Nm
– Ensure 2x mark (2, 3) align
229. If installing new high pressure pump gear – see operation “High
Pressure Pump Gear, Replace (All G9 Engines)” for timing gear
compensation
Page 82 of 103
230. Remove Locking Tool (1) KM-6293 from gear for high pressure pump
232. Install new gasket for timing gear cover to timing gear case
• Clean mating surfaces
233. Remove oil seal for crankshaft pulley (1) from timing gear cover
• Prise out oil seal, using suitable tool
234. Remove oil seal for secondary intermediate gear (2) from timing gear
cover
• Prise out oil seal, using suitable tool
237. Fully install oil seal for crankshaft pulley to timing gear cover
• Use Installer KM-6298
• Locate Sleeve KM-6243-3 (1) onto oil seal
• Rotate nut (2) clockwise, until oil seal fully installed into housing
Note: Stop tightening nut immediately when resistance
experienced.
Page 85 of 103
S 0012717
S 0012716
247. Install air conditioning compressor (2) (if installed) to auxiliary support
bracket
• Install 3x bolt (1) 21 Nm
S 0016497
260. Remove engine with transmission from Engine Overhaul Stand KM-
412
• Remove 2x Stand Adapter KM-412-29 from cylinder block
• Remove 6x bolt (1)
• Remove 8x nut, 8x bolt
Page 95 of 103
S 0012968
263. Install lower section of guide tube for oil level dipstick to engine
• Install new O ring
• Remove blanking plug from engine
• Install bolt 25 Nm
264. Install upper section of guide tube for oil level dipstick to lower section and engine
• Remove blanking plug
• Install new O ring
• Push into lower section of guide tube to secure to 2x clip
• Install bolt 6 Nm
265. Install EGR valve housing (2) with support bracket to engine
• Install 2x bolt (3) 25 Nm
• Secure clip (1)
Page 97 of 103
1 2
S 0013423
268. Install EGR cooler to intake manifold and EGR valve housing
• Clean mating surfaces
• Install new gasket
• Install 7x bolt (1) 25 Nm
Page 98 of 103
S 0016494
269. Install bracket to auxiliary support bracket and EGR valve housing
• Install 2x bolt (2) 15 Nm
1
• Secure 2x harness to bracket
– Secure 2x clip (1)
2 S 0009574
271. Install coolant pipe (1) to coolant pump and thermostat housing
• Remove 2x blanking plug
• Clean mating surfaces
• Install 2x new O ring
– Apply suitable lubricant
• Install bolt (2)
• Push fit
1 2
S 0012891
2
1
S 0012890
276. Install new oil feed pipe (3) to turbocharger and engine
• Remove 4x blanking plug
• Install new O ring
• Secure pipe union 22 Nm
– Use Pipe Spanner KM-812
• Install bolt 15 Nm
• Secure bracket on oil feed pipe to turbocharger
– Install bolt
Page 101 of 103
2 S 0016489
S 0012886
279. Install bracket (2), left side to primary catalytic converter and engine
• Install 3x bolt (1)
• Secure vacuum hose to clip on bracket
280. Install bracket (3), right side to primary catalytic converter and engine
• Install 4x bolt (4)
Page 102 of 103
281. Install power steering pipe assembly with fluid reservoir to engine and transmission assembly
• Install 4x bolt 21 Nm
285. Install engine and transmission to vehicle – see operation “Engine with Transmission, Remove and Install”
286. Remove oil filler cap
287. Fill engine with oil to correct level
288. Install oil filler cap
Page 1 of 1
Measure
– G9U 630
– G9U 730
– M9R 630, M9R 692, M9R 780, M9R 782, M9R 784, M9R 786,
M9R 788
Page 1 of 58
J463810
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
2. Disconnect battery negative lead
3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
1 2
• Release clip (2)
S 0012751
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner (2) and vehicle body 2
• Release 2x clip
S 0012752
1
1
S 0012753
8. Release air flow meter harness (1) from air cleaner support frame (2) 1
• Release clip (3)
2
3
S 0012861
9. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
Page 4 of 58
1 2
S 0012918
10. Release coolant preheater and bracket (1) (if installed) from air cleaner 2
support frame
• Release clip (2)
• Remove bolt (3) 1 3
S 0012860
Page 5 of 58
1 2
3 S 0012862
S 0012741
2 S 0012714
S 0012865
18. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
S 0013065
S 0013066
S 0013067
S 0012872
S 0012873
26. Release fuel rail protector drain hose from engine assembly
• Release 2x clip
27. Disconnect harness connector from exhaust gas recirculation (EGR) module
28. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
29. Lower vehicle
30. Release fluid reservoir for power steering from upper front panel
• Release clip, then pull upwards
31. Remove oil level dipstick (3) from guide tube (4)
32. Release harness from oil level dipstick guide tube
• Release from clip (1)
33. Remove upper section of guide tube (4) from engine
• Remove bolt (2)
• Release 2x clip
• Remove O ring
Page 13 of 58
S 0013070
S 0013069
2 S 0012969
1 2
S 0013073
42. Disconnect harness connector (1) from EGR vacuum control solenoid
(2)
2
1
S 0013074
43. Release engine harness cover from intake manifold, then move to side
• Remove screw (1)
Page 17 of 58
45. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side
• Release from clip on engine lifting eye
• Release 2x integral clip (2)
• Install 2x new blanking plug
Page 18 of 58
2 S 0012995
48. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
49. Disconnect high pressure pipe (2) from high pressure pump 1 2
• Release pipe union (3)
– Use Pipe Spanner KM-812 ; counterhold nut on high pressure
pump using suitable spanner
• Install 2x new blanking plug
50. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Release integral clip
• Install 2x new blanking plug
3 S 0013000
53. Remove high pressure pipe from common rail and cylinder head cover
• Release pipe union (1)
– Use Pipe Spanner KM-812
65. Remove fuel rail protector (1) and gasket from cylinder head
• Remove 2x bolt
• Release grommet (2) from breather pipe connection
Page 23 of 58
68. Remove support bracket for 2x fuel pipe from cylinder head cover
• Remove 2x screw (1)
70. Release 2x fuel pipe (1) from engine mount, then move to one side 1
• Release from 2x clip
S 0012715
71. Remove engine mount with torque reaction link from engine and vehicle
body
• Remove 4x bolt (2), nut (1)
Page 25 of 58
2 S 0012721
1 S 0013075
Install
78. Install 2x new rubber gasket, 7x new seal to new cylinder head cover
• Clean all mating surfaces of cylinder head cover
Page 28 of 58
87. Install engine mount with torque reaction link to engine and vehicle
body
• Install 4x bolt (2), new nut (1); do not tighten at this stage
1
2 S 0012721
3 S 0012724
S 0012715
93. Secure vacuum control valve with support bracket to cylinder head cover
• Install 3x screw
94. Install support bracket for 2x fuel pipe to cylinder head cover
• Install 2x screw (1)
Page 34 of 58
97. Install fuel rail protector (1) and gasket to cylinder head
• Clean mating surfaces, then apply suitable sealant – see “Sealants,
Lubricants and Locking Compounds”
• Position drain hose to rear of engine
• Install 2x bolt; do not tighten at this stage
• Secure grommet (2) to breather pipe connection
Page 35 of 58
S 0013077
110. Install 4x high pressure pipe to common rail and 4x fuel injector; do
not tighten at this stage
• Remove 16x blanking plug
111. Secure 4x high pressure pipe to common rail
• Secure 4x pipe union (1) 22 Nm
– Use Pipe Spanner KM-812
Page 38 of 58
S 0013082
117. Install high pressure pipe (1) to common rail; do not tighten at this
stage
• Remove 2x blanking plug
Page 40 of 58
• Secure to 3x clip
2 S 0012995
129. Install upper section of guide tube (4) for oil level dipstick to lower 1 2 3
section and engine
• Remove blanking plug
• Install new O ring
• Push into lower section of guide tube to secure to 2x clip
• Install bolt (2) 6 Nm
130. Secure harness to guide tube for oil level dipstick 4
• Secure clip (1)
131. Install oil level dipstick to guide tube
• Secure to clip (3)
S 0013070
133. Connect harness connector (1) to EGR vacuum control solenoid (2) 2
1
S 0013074
1 2
S 0013073
2 S 0012969
S 0013069
142. Secure power steering reservoir and support bracket to upper front panel
• Secure to clip
143. Raise vehicle
144. Remove Engine Support KM-6210-A from vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
145. Connect harness connector to EGR module
146. Secure fuel rail protector drain hose to engine assembly
• Secure 2x clip
S 0012873
S 0012872
S 0013067
S 0013066
S 0013065
154. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
S 0013060
S 0012865
2 S 0012714
S 0012741
1 2
3 S 0012862
160. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
161. Install air flow meter harness (1) to air cleaner support frame (2) 1
• Secure clip (3)
2
3
S 0012861
162. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2)
Page 56 of 58
1 3
S 0012860
163. Secure coolant preheater harness (1) (if installed) to air cleaner
support frame (3)
1 2
• Secure clip (2)
S 0012918
1
1
S 0012753
165. Install air intake duct (1) to air cleaner (2) and vehicle body 2
• Secure 2x clip
S 0012752
2
1
3
S 0012749
S 0012751
Measure
L502910
Remove
1. Raise vehicle
2. Disconnect hose assembly (1) for differential pressure sensor from front
exhaust pipe (2), then move to one side
• Counterhold adapter and release union (3)
• Install 2x new blanking plug 1
2 S 0012883
3 S 0014340
2
3
S 0014341
Install
2
3
S 0014341
3 S 0014340
2 S 0012883
J745500
Remove
1. For vehicles with SPS function, download data from engine control unit using Tech 2 or MDI (M9R 692)
Note: Vehicles with IMA injectors, record IMA injector code with Tech 2 or MDI (M9R 692) for reprogramming.
2. Disconnect battery negative lead
3. For vehicles with M9R 780, M9R 782, M9R 784, M9R 786, M9R 788 or
M9R 692 engine, disconnect intake hose from intercooler
• Release clip
S 0012741
1 2
S 0012901
5. Remove bonnet closure switch (if installed) from upper front panel
• Remove bolt
Page 2 of 7
S 0012902
2 S 0012999
1
2
3 S 0013002
Install
3 S 0013002
2 S 0012999
S 0012902
22. Install bonnet closure switch (if installed) to upper front panel
• Install bolt
1 2
S 0012901
24. For vehicles with M9R 780, M9R 782, M9R 784, M9R 786, M9R 788 or
M9R 692 engine, connect intake hose to intercooler
• Secure clip
S 0012741
25. For vehicles with G9U 630 engine, change engine oil and filter – see operation "Engine Oil and Filter, Change”
26. Connect battery negative lead
27. For vehicles with SPS function, program engine control unit using Tech 2 or MDI (M9R 692)
28. Program all volatile memories
Page 1 of 5
J745500
Remove
1. For vehicles with SPS function, download data from engine control unit using Tech 2 or MDI (M9R 630 or M9R 692)
Note: Vehicles with IMA injectors, record IMA injector code with Tech 2 or MDI (M9R 630 or M9R 692) for reprogramming.
2. Disconnect battery negative lead
3. For vehicles with M9R engine, disconnect intake hose from intercooler
• Release clip
S 0012741
1 2
S 0012901
5. Remove bonnet closure switch (if installed) from upper front panel
• Remove bolt
Page 2 of 5
S 0012902
Install
S 0012902
20. Install bonnet closure switch (if installed) to upper front panel
• Install bolt
1 2
S 0012901
22. For vehicles with M9R engine, connect intake hose to intercooler
• Secure clip
S 0012741
23. For vehicles with G9U 630 engine, change engine oil and filter – see operation "Engine Oil and Filter, Change”
24. Connect battery negative lead
25. For vehicles with SPS function, program engine control unit using Tech 2 or MDI (M9R 630 or M9R 692)
26. Program all volatile memories
27. For vehicles with F4R 820 engine, road test vehicle
• In every gear, accelerate under full throttle then decelerate
Page 1 of 2
J472200
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
3. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
4. Lower vehicle
5. Release coolant expansion tank from support bracket and inner wing
• Remove bolt
• Release from inner wing, move to one side
7. Raise vehicle
8. Lower Engine Support KM-6210-A until transmission bracket and engine damping block separate
9. Lower vehicle
10. Remove engine damping block from transmission bracket
Install
15. Secure coolant expansion tank to support bracket and inner wing
• Secure to inner wing
• Install bolt
16. Raise vehicle
17. Remove Engine Support KM-6210-A from vehicle
J472200
Remove
S 0012749
8. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side 1 2
• Release clip (2)
S 0012751
Page 2 of 8
9. Remove air intake duct (1) from air cleaner assembly (2) and front panel
• Release 2x clip 2
S 0012752
1
1
S 0012753
2 S 0012999
3 S 0013002
15. Release engine damping block (1) from transmission bracket and
chassis
• Remove nut (2), 2x bolt (3)
Page 4 of 8
Install
3 S 0013002
2 S 0012999
26. Secure coolant expansion tank to support bracket and inner wing
• Secure to inner wing
• Install bolt
27. Install air intake duct to vehicle
28. Install air cleaner assembly to support frame
• Push on to 4x locating peg (1)
Page 6 of 8
1
1
S 0012753
29. Secure air intake duct (1) to air cleaner assembly (2) and front panel
• Secure 2x clip 2
S 0012752
1 2
S 0012751
31. Connect harness connector (3) to mass air flow meter (1)
32. Connect hose (2) to mass air flow meter 2
• Secure clip
1
3
S 0012749
J472100
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
3. Install Engine Support KM-6210-A to vehicle – see operation “Engine
Support KM-6210-A, Install and Remove”
4. Lower vehicle
5. Release power steering reservoir from front panel, then move to side
• Release from integral clip
Page 2 of 6
6. Release harness (1) and fuel pipe (2) from support bracket
• Release from clip
Install
14. Secure harness (1) and fuel pipe (2) to support bracket
• Secure to clip
Page 6 of 6
FC9 FLA
CHT CHT CHT 10A 40A
4528 4533 4538 105 101
RD 0.5
30 30
RD 7
VT 0.75
VT 0.75
VT 2
1 3
85 30
FB2 X24 X23
1 1 1 1
86 87 15A
K18 1 1
2 5 Y28.1 Y28.2 Y28.3 Y28.4 B34
2 2 2 2 1 2
WH 0.5
BG 0.5
GY 0.5
BN 4/7
GN 0.75
VT 0.75
X24
2 4 3 FB1
4527
25A
CHT ~AC 3136
GN 0.5
AC 3220
GY 0.5
BG 0.5
PK 0.5
VT 0.5
VT 0.5
VT 0.5
WH 2
OG 2
GN 2
GY 2
BG 2
BG 2
BG 2
BG 2
BN 2
MK
PK 2
VT 2
3729
ACK
X54 X56 X55 X54
E3 C4 H1 D1 M3 M4 G1 L1 M1 L4 M4 L3 M3 L2 M2 E1 F1
A25
C4 F3 E2 H2 K2 J1 G2 D4 A3 A4 B3 B4 K4 K3 J2 M1 M2 D1 E2 B2 C2 L4 B1
GN 0.75
WH 0.5
WH 0.5
WH 0.5
WH 0.5
WH 0.5
OG 0.5
OG 0.5
OG 0.5
GN 0.5
GN 0.5
BG 0.5
GY 0.5
GY 0.5
BN 0.5
BN 0.5
BN 0.5
BN 0.5
BN 0.5
PK 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
VT 0.5
1103
VT 1
VT 1
CLS
X103
3 1 3 4 2 1 6 5 4
1 2 3 1 3 6 4 5
2 6 1 5 4 3
2 1 2
BK 1
B117 Y4
1 2
BK 40
16
Systems
ENG9U630 Engine G9U 630, EDC16 C36
Components
A25 Control unit - Diesel, common rail Y4 Solenoid valve - Exhaust gas recirculation
B34 Impulse sensor - Crankshaft Y8 Solenoid valve - Boost pressure regulation
B35 Sensor - Camshaft Y28.1 Injector - Cylinder 1
B46 Air mass meter Y28.2 Injector - Cylinder 2
B117 Sensor - Oxygen, mixture control, heated Y28.3 Injector - Cylinder 3
FB1 Fuse Y28.4 Injector - Cylinder 4
FB2 Fuse Y29 Throttle valve - Positioner
K18 Relay - Engine control unit Y74 Solenoid Valve - Fuel metering
Solenoid valve - Bypass, exhaust gas recirculation
S114 Switch - Water level, fuel filter Y75
cooler
Connectors
X23 Engine & Body front X55 Engine & Control unit - Diesel, common rail X55
X24 Engine & Extension harness, coolant heater X56 Engine & Control unit - Diesel, common rail X56
Engine & Extension harness, solenoid valve -
X54 Engine & Control unit - Diesel, common rail X54 X103
Exhaust gas recirculation
Grounding Points
16 Battery
Abbreviations
10A 10 Ampere CHT Coolant heater
30 Constant voltage CLS Clutch switch
40A 40 Ampere FC9 Fuse FC9
~AC Not air conditioning FLA Main fuse FLA
AC Air conditioning MK Engine cooling
ACK Air conditioning, compressor
Color codes
BG Beige OG Orange
BK Black PK Pink
BN Brown RD Red
GN Green VT Violet
GY Gray WH White
Page 1 of 2
FL11 FC7
70A 10A DIAG HSCAN-L HSCAN-H HSCAN-L HSCAN-H SLS SLS MK MK MK MTA AC ACK
401 147 441 531 533 541 543 732 733 3136 3235 3220 3026 3712 3729
30 15
AC AC AC AC AC
B19
2 3 4 1 6 5
VT 0.5
VT 0.5
WH 0.5
WH 0.5
OG 0.5
BG 0.5
GY 0.5
BG 0.5
BN 0.5
PK 0.5
PK 0.5
VT 0.5
PK 1
X1 X23 X1 X23 X1
A4 A3 2 3 B7 4 C4 C3 C2 C6 C7 C5
YE 0.5/0.75
3018
GN 0.75
VT 0.75
WH 0.5
WH 0.5
WH 0.5
WH 0.5
MTA OG 0.5
OG 0.5
OG 0.5
GN 0.5
GY 0.5
BG 0.5
GY 0.5
BG 0.5
BN 0.5
BN 0.5
PK 0.5
VT 0.5
A25
D2 F4 J2 G3 G4 H1 H4 J4 H4 A2 B3 H1 F2 G1 D2 C2 E1 G2 F3 B1 K2 H3 C3 A4 D3 E3 C1 G3 A3
WH 0.75
BG 0.75
BN 0.75
WH 0.5
WH 0.5
OG 0.5
OG 0.5
OG 0.5
GN 0.5
GN 0.5
GY 0.5
BG 0.5
BG 0.5
BG 0.5
BN 0.5
BN 0.5
BN 0.5
BN 0.5
VT 0.5
VT 0.5
VT 0.5
WH 0.5
RD 7
126
BG 0.5
VT 0.5
STA
X23
4 8 3 2 3 1
2 3 1 1 2 3 8 7 6
3 1 2 1 1
P P
U U
A9 B12 B60 B18 B120 B154 B155 B157 B156
2 7 1 6 2 2 1 2 2
WH 0.5
GY 0.5
PK 0.5
GY 2.5
BN 2.5
PK 2.5
VT 2.5
BK 2
BK 2
BK 2
BK 2
A C B
1P 1P 1P 1P
P
U
B29
R8.1 R8.2 R8.3 R8.4
BK 7
Systems
ENG9U630 Engine G9U 630, EDC16 C36
Components
A9 Control unit - Glow time B154 Sensor - Temperature, Exhaust Gas
A25 Control unit - Diesel, common rail B155 Sensor - Temperature, exhaust gas
B12 Sensor - Coolant temperature B156 Sensor - Temperature, exhaust gas
B18 Sensor - Load pressure B157 Sensor - Pressure, exhaust gas
B19 Sensor - Pedal position R8.1 Glow plug - Cylinder 1
B29 Sensor - Pressure, air conditioning R8.2 Glow plug - Cylinder 2
B60 Sensor - Fuel temperature R8.3 Glow plug - Cylinder 3
B120 Sensor - Fuel rail pressure R8.4 Glow plug - Cylinder 4
Connectors
X1 Instrument panel & Engine X55 Engine & Control unit - Diesel, common rail X55
X23 Engine & Body front X56 Engine & Control unit - Diesel, common rail X56
X54 Engine & Control unit - Diesel, common rail X54
Grounding Points
7 Engine
Abbreviations
10A 10 Ampere FC7 Fuse FC7
15 Ignition voltage FL11 Main fuse FL11
30 Constant voltage HSCAN-H High speed CAN-bus - High
70A 70 Ampere HSCAN-L High speed CAN-bus - Low
AC Air conditioning MK Engine cooling
ACK Air conditioning, compressor MTA Manual transmission automatically shifted
DIAG Diagnostic link SLS Stop lamp switch
DPF Diesel particle filter STA Start & Charging
Color codes
BG Beige PK Pink
BK Black RD Red
BN Brown VT Violet
GN Green WH White
GY Gray YE Yellow
OG Orange
Page 1 of 2
15 30
B12 M19
B18 M20
B19 R27
B29 Y8
B34 Y10
B35 Y28.1
B46 Y28.2
B60 Y28.3
B120 Y28.4
B154 Y74
B155 Y75
B156
A25 R8.1
R8.2
B157 A9
R8.3
R8.4
G2 B117
S43 X13
S95.3 Y4
S104 Y29
S114
A1
HSCAN
A30
A42
H1
31 P122640
Block Diagram Vivaro, model year 2007
Page 2 of 2
Components
A1 Control unit - Airbag M19 Motor - Radiator fan
A9 Control unit - Glow time M20 Motor - Radiator fan
A25 Control unit - Diesel, common rail R8.1 Glow plug - Cylinder 1
Control unit - Manual transmission automatically
A30 R8.2 Glow plug - Cylinder 2
shifted
Control unit - Anti-Lock Brake System &
A42 R8.3 Glow plug - Cylinder 3
Electronic stability program
B12 Sensor - Coolant temperature R8.4 Glow plug - Cylinder 4
B18 Sensor - Load pressure R27 Heating resistor - Coolant heater
B19 Sensor - Pedal position S43 Switch - Stop lamp, double
B29 Sensor - Pressure, air conditioning S95.3 Switch - Air conditioning
B34 Impulse sensor - Crankshaft S104 Switch - Clutch Pedal
B35 Sensor - Camshaft S114 Switch - Water level, fuel filter
B46 Air mass meter Y4 Solenoid valve - Exhaust gas recirculation
B60 Sensor - Fuel temperature Y8 Solenoid valve - Boost pressure regulation
B117 Sensor - Oxygen, mixture control, heated Y10 Clutch - Compressor, air conditioning
B120 Sensor - Fuel rail pressure Y28.1 Injector - Cylinder 1
B154 Sensor - Temperature, Exhaust Gas Y28.2 Injector - Cylinder 2
B155 Sensor - Temperature, exhaust gas Y28.3 Injector - Cylinder 3
B156 Sensor - Temperature, exhaust gas Y28.4 Injector - Cylinder 4
B157 Sensor - Pressure, exhaust gas Y29 Throttle valve - Positioner
G2 Alternator Y74 Solenoid Valve - Fuel metering
Solenoid valve - Bypass, exhaust gas recirculation
H1 Instrument Y75
cooler
Connectors
X13 Diagnostic link
Abbreviations
15 Ignition voltage 31 Ground
30 Constant voltage HSCAN High speed CAN-bus
Page 1 of 3
J451900
Remove
S 0012523
Page 2 of 3
Install
S 0012523
N221950
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
3. Remove oil level sensor from cylinder block
• Disconnect harness connector (1)
• Remove 2x bolt (2)
Install
J451700
Remove
1
2
S 0013130
Measure
Install
17. Install oil pressure switch (2) 20 Nm to engine oil filter housing
• Install new seal ring to oil pressure switch
• Connect harness connector (1)
J451700
Remove
4. Remove oil pressure switch (1) from oil filter housing (2) 1 2
• Place collecting container below
• Disconnect harness connector
S 0013032
Measure
Install
16. Install oil pressure switch (1) to oil filter housing (2) 20 Nm
• Install new seal ring to oil pressure switch
1 2
• Connect harness connector
S 0013032
Remove
Install
J451500
Adjust
S 0012716
6. Install Positioning Pin KM-6203 (arrowed), through oil filter housing into
crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
Page 2 of 13
7. Apply match mark (1) on crankshaft pulley, 180° fro m top dead centre
(2), 2x match mark (3) on crankshaft pulley and engine
Note: These provide reference marks for positioning crankshaft when
checking cylinders 2, 3, & 4.
Page 3 of 13
8. Remove Positioning Pin KM-6203 (arrowed) from crankshaft and oil filter
housing
Remove
12. Disconnect hose (2) from mass air flow meter (1)
• Release clip
13. Disconnect harness connector (3) from mass air flow meter
Page 5 of 13
14. Remove air intake duct (1) from air cleaner assembly (2) and front
panel
• Release 2x clip
16. Release harness (1) for mass air flow meter from support frame (2)
• Release clip (3)
17. Release harness for coolant heater assembly from support frame
• Release clip (2)
18. Release bracket with coolant heater assembly (1) from support frame
• Remove bolt (3)
Page 7 of 13
Measure
Page 8 of 13
Install
40. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
41. Secure bracket with coolant heater assembly (1) to support frame
• Install bolt (3)
42. Secure harness for coolant heater assembly to support frame
• Secure clip (2)
Page 11 of 13
44. Secure air intake duct (1) to air cleaner assembly (2) and front panel
• Secure 2x clip
Page 12 of 13
45. Connect harness connector (3) to mass air flow meter (1)
46. Connect hose (2) to mass air flow meter
• Secure clip
J338000
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
3. Remove lower engine stabiliser (1) from engine mount bracket and
subframe
• Remove 2x bolt (2)
Install
J339100
Remove
1. Remove upper engine stabiliser (1) from support bracket and chassis
• Remove 2x bolt (2)
Install
J450100
Important: Never lower the vehicle onto its wheels without the drive shafts installed correctly, as this will damage the wheel bearings.
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
Important: Observe the relevant safety regulations when working on air conditioning systems.
2. For vehicle with air conditioning, evacuate refrigerant from air conditioning circuit – see operation “Air Conditioning System, Evacuate
and Fill”
3. Disconnect battery negative lead
4. Remove cap from coolant expansion tank
5. Raise vehicle
6. Remove engine and transmission undershield from vehicle
• Remove 8x bolt
S 0012760
13. Remove upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
14. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
Page 4 of 83
1 2
S 0012751
15. Disconnect hose (2) from mass air flow meter (1)
• Release clip
16. Disconnect harness connector (3) from mass air flow meter
2
1
3
S 0012749
17. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
Page 5 of 83
S 0012752
1
1
S 0012753
19. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
Page 6 of 83
1
2
3
S 0012861
20. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
1 2
S 0012918
21. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Release clip (2)
• Remove bolt (3)
Page 7 of 83
1 3
S 0012860
22. Remove support frame for air cleaner assembly from engine compartment
• Remove 2x nut
S 0012834
28. Disconnect harness connector (2) (if installed) from pressure sensor (1)
for air conditioning
S 0012835
30. Disconnect 2x refrigerant pipe (1) (if installed) from air conditioning
condenser (3)
• Remove 2x bolt (2), then move to one side
• Remove 2x O ring
• Install 4x new blanking plug
31. Remove radiator assembly with air conditioning condenser (if installed) from support crossmember
Note: 2x technician are required.
32. Disconnect harness connector from air conditioning compressor (if installed)
33. Remove intercooler pipe from vehicle
• Disconnect intercooler pipe from exhaust gas
recirculation (EGR) valve housing
– Release clip (1) from transmission
– Release clip (3)
• Disconnect harness connector from charge
pressure sensor (4)
• Release coolant hose from clip (2)
Page 11 of 83
2 S 0014441
S 0012865
S 0012870
S 0012722
2
3
4 S 0016919
2 S 0012883
2 S 0012884
S 0012885
66. Disconnect harness connector (1) from crankshaft inductive pulse pick-
up
67. Release harness from 2x bracket, then move to one side
• Release 2x clip (2, 3)
Page 21 of 83
2 3
1
S 0013176
S 0013177
70. For right drive vehicles, release power steering pipe from bracket on
steering gear
• Remove nut (1)
S 0012504
S 0013067
S 0013069
80. Release harness for crankshaft inductive pulse pick-up from rear engine lifting eye
• Release clip
2 S 0012969
83. Disconnect harness connector (1) from EGR vacuum control solenoid
(2)
2
1
S 0013074
86. Release vacuum control valve with support bracket from cylinder head cover, then move to one side
• Remove 3x screw
87. Disconnect 2x hose for coolant expansion tank from thermostat housing
• Release 2x clip
S 0014493
89. Disconnect coolant hose for EGR cooler from thermostat housing
• Release clip
S 0014494
91. Disconnect coolant hose for EGR cooler from turbocharger coolant hose (if installed)
• Release clip
92. Remove bracket (1) from auxiliary support bracket and EGR valve
housing
• Remove 2x bolt (2)
• Release 2x harness from bracket
– Release 2x clip (3)
2
3 S 0012765
S 0013268
3 2 S 0014185
99. For vehicles with PF6 transmission, release 2x gearshift cable (1, 4)
from transmission
• Release 2x ball joint (3, 5) using Remover KM-569-A
• Release 2x cable from bracket (2)
– Pull 2x locking ring rearwards, then slide off bracket and move
to one side
Page 31 of 83
100. For vehicles with PF6 transmission, disconnect harness connector (1)
from reverse lamp switch
Page 32 of 83
101. For vehicles with PF6 transmission, disconnect harness connector (1)
from vehicle speed sensor (if installed)
102. For vehicles with tachograph, disconnect harness connector (1) from
vehicle speed sensor
Note: As the tamper-proof seal is not cut, seal replacement and
calibration will not be required.
• Rotate anti-clockwise, then pull off
Page 33 of 83
2 S 0013387
104. Release earth lead from transmission, then move to one side
• Remove bolt (1)
Page 34 of 83
2 S 0009699
1
S 0013178
107. For vehicles with PF6R transmission, remove transmission control unit
from bracket
• Release rubber strap (1)
• Disconnect 2x harness connector (2)
– Release 2x clip (3)
1
108. For vehicles with PF6R transmission, release harness from cover
• Release 2x clip
2 S 0012999
S 0012800
111. For vehicles with protection cover, disconnect fuel pipe (1) from fuel
filter housing
• Release clip
• Install 2x new blanking plug
112. Release fuel filter housing from support bracket
• Release clip, then pull upwards
113. For vehicles with protection cover, disconnect harness connector (2)
from fuel filter housing
114. Disconnect harness connector from sensor for water ingress (if
installed)
115. Remove protection cover (1) from fuel filter housing
• Rotate locking ring anti-clockwise, then lift off
116. Disconnect fuel feed pipe (3) for high pressure pump from fuel filter
housing
Page 37 of 83
• Release clip
• Install 2x new blanking plug
118. Release 2x fuel pipe (1) from bracket, then move to one side
• Release from 2x clip
Page 38 of 83
S 0012715
119. Disconnect pipe (1) from vacuum pump, then move to one side
• Release integral clip
• Install new blanking plug
S 0014492
121. Disconnect refrigerant pipe (1) from air conditioning compressor (if
installed)
• Remove bolt (2), then move to one side
• Remove O ring
• Install 2x new blanking plug
122. Release power steering hose assembly from radiator support crossmember
• Remove 2x bolt
Important: Observe relevant environmental regulations when disposing of used power steering fluid.
124. Drain fluid from power steering reservoir
• Remove cap
• Place collecting container below
125. Position power steering reservoir with power steering pipe assembly to engine
• Secure using suitable method
126. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
2 S 0012721
S 0013299
Install
S 0013299
3
5 4 S 0013084
143. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
Page 44 of 83
S 0013060
144. Release power steering reservoir with power steering pipe assembly from engine
• Position to one side for installation at a later stage
S 0012715
149. For vehicles without protection cover, connect fuel feed pipe for high pressure pump to fuel filter housing
• Remove 2x blanking plug
• Secure 2x integral clip
S 0012800
151. For vehicles with protection cover, connect fuel feed pipe (3) for high
pressure pump to fuel filter housing
• Remove 2x blanking plug
• Secure clip
152. Install protection cover (1) to fuel filter housing
• Push on, then rotate locking ring clockwise
153. Connect harness connector (2) to fuel filter housing
154. Connect harness connector to sensor for water ingress (if installed)
155. For vehicles with protection cover, secure fuel filter housing to support
bracket
• Secure to clip
156. Connect fuel pipe (1) to fuel filter housing
• Remove 2x blanking plug
• Secure clip
Page 47 of 83
159. For vehicles with PF6R transmission, install transmission control unit
to bracket
• Connect 2x harness connector (2)
– Secure 2x clip (3)
1
• Secure rubber strap (1)
160. For vehicles with PF6R transmission, secure harness to cover
• Secure 2x clip
2 S 0012999
1
S 0013178
163. For vehicles with PF6R transmission, connect harness connector (1)
to hydraulic shifting assembly
• Secure clip (2)
Page 50 of 83
2 S 0009699
2 S 0013387
166. For vehicles with PF6 transmission, connect harness connector (1) to
vehicle speed sensor (if installed)
167. For vehicles with PF6 transmission, connect harness connector (1) to
reverse lamp switch
Page 52 of 83
168. For vehicles with PF6 transmission, secure 2x gearshift cable (1, 4) to
transmission
• Secure to bracket (2)
– Slide on
• Secure 2x ball joint (3, 5)
– Push on
Page 53 of 83
3 2 S 0014185
S 0013268
175. Install bracket (1) to auxiliary support bracket and EGR valve housing
• Install 2x bolt (2) 15 Nm
• Secure 2x harness to bracket
– Secure 2x clip (3)
Page 56 of 83
3 S 0012765
176. Connect coolant hose for EGR cooler to turbocharger coolant hose (if installed)
• Secure clip
S 0014494
S 0014493
2
1
S 0013074
2 S 0012969
S 0013069
S 0013067
194. Secure harness for crankshaft inductive pulse pick-up to rear engine lifting eye
• Secure clip
195. Raise vehicle
196. Secure trunking (1) to transmission
• Install bolt (arrowed)
S 0013177
S 0014492
S 0013176
S 0012885
204. Connect hose assembly (1) for differential pressure sensor to front
exhaust pipe (2)
• Remove 2x blanking plug
• Apply suitable sealant to hose assembly
• Counterhold adapter and secure union (3) 21 Nm
Page 65 of 83
2 S 0012883
2 S 0012884
207. For right drive vehicles, secure power steering pipe to bracket on
steering gear
• Install nut (1)
S 0012504
211. Install new output seal (3) to transmission housing, right side
• Position guide sleeve (2) with output seal (3) into Installer KM-
6434 (1)
• Use soft-faced hammer
Important: Ensure that the bearing retaining plate is installed in the correct
orientation as observed on removal.
215. Install drive shaft to transmission, right side
• Install new retainer plate
– Install new O ring
• Install 2x bolt (1) 8 Nm
Important: 2nd technician is required to guide the drive shaft into the transmission to prevent damage to the seal.
217. Install drive shaft to transmission, left side
218. Secure 2x steering knuckle to 2x strut assembly
• Install 4x bolt, 4x new nut (1) 180 Nm
2
3
4 S 0016919
221. Install 2x new nut (1) to 2x drive shaft; do not tighten at this stage
Page 71 of 83
S 0012722
S 0012870
S 0012865
2 S 0014441
S 0012835
246. Connect harness connector (2) to pressure sensor (1) for air
conditioning (if installed)
S 0012834
255. Install support frame for air cleaner assembly to engine compartment
• Install 2x nut 8 Nm
256. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
1
2
3
S 0012861
257. Secure bracket with coolant heater assembly (1) (if installed) to
support frame
• Install bolt (3)
258. Secure harness for coolant heater assembly (if installed) to support
frame
• Secure clip (2)
Page 81 of 83
1 3
S 0012860
259. Install upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
260. Refill air conditioning system – see operation “Air Conditioning System, Evacuate and Charge”
261. Bleed power steering system – see operation “Hydraulic System, Bleed”
262. Bleed hydraulic clutch system – see operation “Hydraulic Clutch Operation, Bleed”
• For PF6
• For PF6R
263. Connect battery negative lead
264. Program all volatile memories
265. Bleed hydraulic shifting assembly (if required) – see operation “Hydraulic Shifting Assembly, Bleed”
Note: The hydraulic shifting assembly will require bleeding if air has entered the system when replacing the relevant components
whilst the hydraulic shifting assembly was removed.
266. Program hydraulic shifting assembly – see operation “Hydraulic Shifting Assembly, Program”
267. Bleed cooling system – see operation “Cooling System, Drain and Refill”
268. Remove engine immobiliser/instrument panel fuse
from interior fuse box
Note: The Turbocharger will only require priming
if the engine with transmission is being installed
after performing an engine overhaul operation
and if the oil circuit has been opened.
• Remove left ashtray housing from instrument
panel
– Release 4x clip
Page 82 of 83
269. To prime oil circuit, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
270. Install engine immobiliser/instrument panel fuse to interior fuse box
271. Install left ashtray housing to instrument panel
• Secure 4x clip
272. Start engine and allow to run until normal operating temperature attained
273. Stop engine
274. Check engine oil level, top up if necessary
275. Raise vehicle
276. Install radiator undershield to support crossmember
• Install bolt 6 Nm
Engine, Replace
J450075
Remove
1. Remove engine and transmission from vehicle – see operation “Engine with Transmission, Remove and Install”
Important: Observe the relevant environmental regulations when disposing
of used lubricants.
2. Disconnect feed hose (1) from power steering pump
• Place collecting container below
• Release clip
• Install 2x new blanking plug
• Remove O ring
• Install 2x new blanking plug
5. Remove power steering pipe assembly with fluid reservoir from engine and transmission assembly
• Remove 4x bolt
Page 2 of 43
6. Remove bracket (2), left side, from primary catalytic converter and
engine
• Remove 3x bolt (1)
• Release vacuum hose from clip on bracket
7. Remove bracket (3), right side, from primary catalytic converter and
engine
• Remove 4x bolt (4)
S 0012886
2
1
S 0012890
1 2
S 0012891
13. Remove coolant pipe (1) from coolant pump and thermostat housing
• Place collecting container below
• Remove bolt (2)
• Pull out coolant pipe
• Remove 2x O ring
• Install 2x new blanking plug
Page 5 of 43
16. Remove exhaust gas recirculation (EGR) vacuum control solenoid (1)
with bracket from cylinder head cover
• Remove 3x screw (2)
1
S 0013280
17. Remove bracket from auxiliary support bracket and EGR valve housing
• Remove 2x bolt (2)
• Release 2x harness from bracket
– Release 2x clip (1)
Page 7 of 43
2 S 0009574
S 0016515
20. Remove EGR cooler from intake manifold and EGR valve housing
• Remove 7x bolt (1), gasket
Page 8 of 43
S 0016494
21. Remove EGR valve housing (2) with support bracket from engine
• Release clip (1)
• Remove 2x bolt (3)
1 2
S 0013423
22. Remove upper section of guide tube for oil level dipstick from lower section
• Remove bolt
• Pull guide tube upwards, then release 2x clip
• Remove O ring
23. Remove lower section of guide tube for oil level dipstick from engine
• Remove bolt
• Withdraw lower section
• Install new blanking plug to engine
• Remove O ring
S 0012968
S 0016497
39. Remove air conditioning compressor (2) (if installed) from auxiliary
support bracket
• Remove 3x bolt (1)
Page 17 of 43
S 0012852
48. Remove drain hose for fuel rail protector from engine
• Release clip (1)
• Remove bolt
Page 20 of 43
Important: Observe the relevant environmental regulations when disposing of used engine oil.
49. Drain engine oil
• Place collecting container below
• Remove drain plug
• Remove sealing washer
50. Install drain plug 25 Nm
• Install sealing washer
51. Install engine hoist to engine
• Install lifting chain to engine
• Adjust engine hoist until weight of engine fully supported
52. Remove engine from Engine Overhaul Stand KM-412
• Remove 2x Stand Adapter KM-412-29 from cylinder block
• Remove 6x bolt
• Remove 8x nut, 8x bolt
53. Install oil filler cap to engine
Install
Important: The oil filler cap is removed to prevent it from being damaged, when the lifting chain is fully supporting the weight of the
engine.
54. Remove oil filler cap
55. Install engine hoist to new engine
• Install lifting chain to engine
• Adjust engine hoist until weight of engine fully supported
56. Install engine with transmission to Engine Overhaul Stand KM-412
• Install 2x Stand Adapter KM-412-29 to cylinder block
• Install 6x bolt
57. Install 2x Stand Adapter KM-412-29 to Engine Overhaul Stand KM-412
• Install 8x bolt, 8x nut
S 0012716
59. Install Positioning Pin KM-6203 through oil filter housing into crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
Page 22 of 43
PMH
S 0017785
61. Install Flywheel Positioning Tool KM-6403 (1) to cylinder block and
flywheel
• Push fit
– Position flywheel as necessary to ensure full location of tool
63. Remove Flywheel Positioning Tool KM-6403 (1) from cylinder block
and flywheel
• Pull out
Page 24 of 43
S 0012717
S 0012716
Important: Side (A) must be installed facing clutch pressure plate end.
67. Install clutch plate with Alignment Tool KM-6165 to flywheel
Page 26 of 43
S 0017939
2 9
6 4
5 1 3
7 8
S 0012859
73. Install air conditioning compressor (2) (if installed) to auxiliary support
bracket
• Install 3x bolt (1) 21 Nm
S 0016497
S 0012968
89. Install lower section of guide tube for oil level dipstick to engine
• Install new O ring
• Remove blanking plug from engine
• Install bolt 25 Nm
90. Install upper section of guide tube for oil level dipstick to lower section and engine
• Remove blanking plug
• Install new O ring
• Push into lower section of guide tube to secure to 2x clip
• Install bolt 6 Nm
91. Install EGR valve housing (2) with support bracket to engine
• Install 2x bolt (3) 25 Nm
• Secure clip (1)
Page 35 of 43
1 2
S 0013423
94. Install EGR cooler to intake manifold and EGR valve housing
• Clean mating surfaces
• Install new gasket
• Install 7x bolt (1) 25 Nm
Page 36 of 43
S 0016494
S 0016515
97. Install bracket to auxiliary support bracket and EGR valve housing
• Install 2x bolt (2) 15 Nm
• Secure 2x harness to bracket
– Secure 2x clip (1)
Page 37 of 43
2 S 0009574
98. Install EGR vacuum control solenoid (1) with bracket to cylinder head
cover
• Install 3x screw (2)
1
S 0013280
101. Install coolant pipe (1) to coolant pump and thermostat housing
• Remove 2x blanking plug
• Clean mating surfaces
• Install 2x new O ring
– Apply suitable lubricant
• Install bolt (2)
• Push fit
Page 39 of 43
S 0012891
2
1
S 0012890
106. Install new oil feed pipe (3) to turbocharger and engine
• Remove 4x blanking plug
• Install new O ring
• Secure pipe union 22 Nm
– Use Pipe Spanner KM-812
• Install bolt 15 Nm
• Secure bracket on oil feed pipe to turbocharger 1
– Install bolt
S 0012886
109. Install bracket (2), left side to primary catalytic converter and engine
• Install 3x bolt (1)
• Secure vacuum hose to clip on bracket
110. Install bracket (3), right side to primary catalytic converter and engine
• Install 4x bolt (4)
Page 42 of 43
111. Install power steering pipe assembly with fluid reservoir to engine and transmission assembly
• Install 4x bolt 21 Nm
115. Install engine and transmission to vehicle – see operation “Engine with Transmission, Remove and Install”
116. Remove oil filler cap
117. Fill engine with oil to correct level
118. Check engine oil level, top up if necessary
Page 1 of 36
J470300
Remove
S 0012751
5. Release air intake duct (1) from air cleaner assembly (2)
• Release 2x clip
Page 2 of 36
S 0012752
1
1
S 0012753
7. Release harness for coolant heater assembly (if installed) from support
frame
• Release clip (2)
8. Release bracket with coolant heater assembly (1) (if installed) from
support frame
• Remove bolt (3)
Page 3 of 36
9. Release harness (1) for mass air flow meter from support frame (2)
• Release clip (3)
Page 4 of 36
1 2
3 S 0012862
2 S 0012714
S 0012865
S 0012870
S 0012722
S 0012872
2
3
4 S 0016919
22. Release 2x harness (if installed) for 2x ABS sensor from subframe and 2x lower arm
• Release from 6x clip
• Release from 2x bracket
23. Raise vehicle
24. Remove engine and transmission undershield from vehicle
• Remove 8x bolt
25. Release 2x brake pipe from subframe
• Release 2x clip
5
S 0012879
1 2
3
S 0012881
33. Remove subframe with steering gear and 2x lower arm from vehicle
Note: Illustration shows jack removed for clarity.
• Remove 2x bolt (1)
34. Disconnect hose assembly (1) for differential pressure sensor from front
exhaust pipe (2), then move to one side
• Counterhold adapter and release union (3)
• Install 2x new blanking plug
Page 12 of 36
2 S 0012883
2 S 0012884
S 0012885
38. Remove bracket (2), left side, from primary catalytic converter and
engine
• Remove 3x bolt (1)
• Release vacuum hose from clip on bracket
39. Remove bracket (3), right side, from primary catalytic converter and
engine
• Remove 4x bolt (4)
Page 14 of 36
S 0012873
41. Remove 2x clip from 2x harness for oxygen sensor and turbocharger temperature sensor
42. Remove primary catalytic converter (1) from turbocharger
• Remove 4x nut (2), gasket 1
S 0012886
5
4
3 S 0012887
2
1
S 0012890
1 2
S 0012891
S 0012852
Install
Page 18 of 36
2 9
6 4
5 1 3
7 8
S 0012859
S 0012891
2
1
S 0012890
S 0012886
S 0012873
61. Install bracket (2), left side, to primary catalytic converter and engine
• Install 3x bolt (1)
• Secure vacuum hose to clip on bracket
62. Install bracket (3), right side, to primary catalytic converter and engine
• Install 4x bolt (4)
Page 21 of 36
63. Install 2x clip to 2x harness for oxygen sensor and turbocharger temperature sensor
64. Install front exhaust pipe to diesel particulate filter
• Clean mating surfaces
• Install new gasket
• Install 2x new nut; do not tighten at this stage
65. Secure front exhaust pipe to primary catalytic converter
• Clean mating surfaces
• Install new gasket
• Install 2x new nut; do not tighten at this stage
66. Secure 4x nut 21 Nm
Page 22 of 36
S 0012885
67. Connect hose assembly (1) for differential pressure sensor to front
exhaust pipe (2)
• Remove 2x blanking plug
• Apply suitable sealant to hose assembly
• Counterhold adapter and secure union (3) 21 Nm
Page 23 of 36
2 S 0012883
2 S 0012884
69. Install subframe with steering gear and 2x lower arm to vehicle
Note: Illustration shows jack removed for clarity.
• Apply locking compound to 2x bolt – see “Sealants, Lubricants and
Locking Compounds”
• Install 2x bolt (1) 60 Nm
Page 24 of 36
70. For vehicles with additional heater, install reaction link, left side to
chassis
• Install bolt (1); do not tighten at this stage
1 2 3 4
5
S 0012879
1 2
3
S 0012881
2
3
4 S 0016919
81. Secure 2x harness (if installed) for 2x ABS sensor to subframe and 2x lower arm
• Secure to 6x clip
• Secure to 2x bracket
S 0012872
S 0012722
S 0012870
S 0012865
2 S 0012714
Page 32 of 36
1 2
3 S 0012862
98. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
1
2
3
S 0012861
99. Secure bracket with coolant heater assembly (1) (if installed) to support
frame
• Install bolt (3)
100. Secure harness for coolant heater assembly (if installed) to support
frame
• Secure clip (2)
Page 33 of 36
1 3
S 0012860
1
1
S 0012753
102. Secure air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
Page 34 of 36
S 0012752
103. Connect harness connector (3) to mass air flow meter (1)
104. Connect hose (2) to mass air flow meter 2
• Secure clip
1
3
S 0012749
1 2
S 0012751
109. To prime turbocharger, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
110. Install engine immobiliser/instrument panel fuse to interior fuse box
111. Install left ashtray housing to instrument panel
• Secure 4x clip
112. Bleed power steering system – see operation “Hydraulic System, Bleed”
113. Refill coolant expansion tank to maximum level
114. Start engine, and run until the oil pressure indicator lamp is extinguished
115. Stop engine
116. Check engine oil level, top up if necessary
Page 1 of 4
J817900
Remove
1. Release oil filler cap assembly from air cleaner assembly, then move to
one side
Note: The securing screws are part of the oil filler cap assembly.
• Release 2x screw (1) 1
S 0012711
Install
S 0012711
Page 1 of 3
J491100
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed. Refer to "Safety Regulations – Engine, Fuel and Exhaust System" . Do not loosen or remove fuel lines when the engine is
running. As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent
pollutants from penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and
moisture may collect in the connections causing electrical problems.
1. Remove air cleaner assembly and necessary components to gain access to fuel leak-off pipe
Important: Clean pipe connections before disconnecting with lint-free cloth.
2. Disconnect fuel leak-off pipe from 4x fuel injector
• Release 4x spring clip
– Push in
Measure
Install
Important: The fuel leak-off pipe and temperature sensor assembly must
always be replaced once disconnected.
11. Replace fuel leak-off pipe and temperature sensor assembly
Page 3 of 3
12. Install air cleaner assembly and components previously removed in step 1
Page 1 of 37
J491060
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
2. Disconnect battery negative lead
3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
S 0012752
1
1
S 0012753
8. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
1
2
3
S 0012861
9. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
Page 4 of 37
1 2
S 0012918
10. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Release clip (2)
• Remove bolt (3) 2
1 3
S 0012860
Page 5 of 37
1 2
3 S 0012862
S 0012741
2 S 0012714
S 0012865
18. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
S 0013065
S 0013066
S 0013067
S 0013069
2 S 0012969
1 2
S 0013073
30. Disconnect harness connector (1) from EGR vacuum control solenoid
(2)
2
1
S 0013074
31. Release engine harness cover from intake manifold, then move to side
• Remove screw (1)
Page 15 of 37
32. Remove oil level dipstick (3) from guide tube (4)
33. Release harness from oil level dipstick guide tube
• Release from clip (1)
1 2 3
34. Remove upper section of guide tube (4) from engine
• Remove bolt (2)
• Release 2x clip
• Remove O ring
• Install new blanking plug
4
S 0013070
36. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side
• Release from clip on engine lifting eye
• Release 2x integral clip (2) 1
• Install 2x new blanking plug
2 S 0012995
39. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
42. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Install new blanking plug
• Release 2x integral clip
• Install 2x new blanking plug
Install
44. Install 4x new high pressure pipe (1) to common rail and 4x fuel
injector; do not tighten at this stage
• Remove 16x blanking plug
45. Secure 4x high pressure pipe to common rail
• Secure 4x pipe union 22 Nm
– Use Pipe Spanner KM-812
S 0009855
50. Install new fuel leak-off pipe (1) with fuel temperature sensor to high
pressure pump
• Remove 2x blanking plug
• Secure integral clip
2 S 0012995
56. Install upper section of guide tube (4) for oil level dipstick to lower
section and engine
• Remove blanking plug
• Install new O ring 1 2 3
• Push into lower section of guide tube to secure to 2x clip
• Install bolt (2) 6 Nm
57. Secure harness to guide tube for oil level dipstick
• Secure clip (1)
58. Install oil level dipstick to guide tube 4
• Secure to clip (3)
S 0013070
60. Connect harness connector (1) to EGR vacuum control solenoid (2)
2
1
S 0013074
1 2
S 0013073
2 S 0012969
S 0013069
S 0013067
S 0013066
S 0013065
72. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
S 0013060
S 0012865
2 S 0012714
S 0012741
1 2
3 S 0012862
78. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
79. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
1
2
3
S 0012861
80. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2)
Page 35 of 37
1 3
S 0012860
81. Secure coolant preheater harness (1) (if installed) to air cleaner support
frame (3)
• Secure clip (2)
1 2
S 0012918
1
1
S 0012753
83. Install air intake duct (1) to air cleaner (2) and vehicle body
• Secure 2x clip
S 0012752
2
1
3
S 0012749
1 2
S 0012751
J491070
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
2. For vehicles with SPS function, download data from engine control unit using Tech 2
Note: Vehicles with IMA injectors, record IMA injector code with Tech 2 for reprogramming.
3. Disconnect battery negative lead
4. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
2
1
3
S 0012749
7. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
2
S 0012752
1
1
S 0012753
9. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
1
2
3
S 0012861
10. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
Page 4 of 43
1 2
S 0012918
11. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame 2
• Release clip (2)
• Remove bolt (3)
1 3
S 0012860
Page 5 of 43
1 2
3 S 0012862
S 0012741
2 S 0012714
S 0012865
19. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
S 0013065
S 0013066
S 0013067
S 0013069
2 S 0012969
1 2
S 0013073
31. Disconnect harness connector (1) from EGR vacuum control solenoid
(2) 2
1
S 0013074
32. Release engine harness cover from intake manifold, then move to side
• Remove screw (1)
Page 15 of 43
33. Remove oil level dipstick (3) from guide tube (4)
34. Release harness from oil level dipstick guide tube
1 2 3
• Release from clip (1)
35. Remove upper section of guide tube (4) from engine
• Remove bolt (2)
• Release 2x clip
• Remove O ring
• Install new blanking plug
4
S 0013070
37. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side 1
• Release from clip on engine lifting eye
• Release 2x integral clip (2)
• Install 2x new blanking plug
2 S 0012995
40. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
41. Disconnect high pressure pipe (2) from high pressure pump
• Release pipe union (3)
– Use Pipe Spanner KM-812 ; counterhold nut on high pressure
pump using suitable spanner
• Install 2x new blanking plug
42. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Release integral clip
• Install 2x new blanking plug
Page 18 of 43
1 2
3 S 0013000
45. Remove high pressure pipe from common rail and cylinder head cover
• Release pipe union (1)
– Use Pipe Spanner KM-812
Install
Important: Each fuel injector used in the EDC 16 fuel injection system is
calibrated with a specific code sequence to ensure correct and precise flow.
This process, known as IMA calibration, requires that a specific seven-digit
code must be programmed into the engine control unit with Tech 2. This
code (1) is printed on the fuel injector.
55. For each new fuel injector, carefully record code (1) and cylinder to
which injector is to be installed
Note: No. 1 cylinder is at the transmission end of the engine.
Note: The letters J and Q, and the numbers 0 and 9 are not used in
IMA coding. To assist identification of characters in the code, compare
other characters displayed on the injector. In the illustation, the IMA
code shown is 68HV7i1.
Page 21 of 43
S 0014633
65. Install 4x high pressure pipe (1) to common rail and 4x fuel injector; do
not tighten at this stage
• Remove 16x blanking plug
66. Secure 4x high pressure pipe to common rail
• Secure 4x pipe union 22 Nm
– Use Pipe Spanner KM-812
S 0009855
71. Install high pressure pipe (1) to common rail; do not tighten at this stage
• Remove 2x blanking plug
76. Install new fuel leak-off pipe with fuel temperature sensor to high pressure pump
• Remove 2x blanking plug
• Secure integral clip
77. Connect fuel leak-off pipe to common rail
• Remove 2x blanking plug
• Secure 2x integral clip
2 S 0012995
82. Install upper section of guide tube (4) for oil level dipstick to lower
section and engine
• Remove blanking plug
• Install new O ring
• Push into lower section of guide tube to secure to 2x clip
• Install bolt (2) 6 Nm
83. Secure harness to guide tube for oil level dipstick
• Secure clip (1)
84. Install oil level dipstick to guide tube
• Secure to clip (3)
Page 29 of 43
1 2 3
S 0013070
86. Connect harness connector (1) to EGR vacuum control solenoid (2)
Page 30 of 43
2
1
S 0013074
1 2
S 0013073
2 S 0012969
S 0013069
S 0013067
S 0013066
S 0013065
98. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
Page 35 of 43
S 0013060
S 0012865
2 S 0012714
2 S 0012714
1 2
3 S 0012862
104. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
105. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
Page 40 of 43
1
2
3
S 0012861
106. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame 2
• Install bolt (3)
• Secure clip (2)
1 3
S 0012860
107. Secure coolant preheater harness (1) (if installed) to air cleaner
support frame (3)
• Secure clip (2)
Page 41 of 43
1 2
S 0012918
1
1
S 0012753
109. Install air intake duct (1) to air cleaner (2) and vehicle body
• Secure 2x clip
Page 42 of 43
S 0012752
S 0012749
1 2
S 0012751
J491850
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
2. Disconnect battery negative lead
3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner assembly (2) and front panel
• Release 2x clip
2
S 0012752
1
1
S 0012753
8. Release harness (1) for mass air flow meter from support frame (2)
• Release clip (3)
1
2
3
S 0012861
9. Release harness for coolant heater assembly (if installed) from support
frame
• Release clip (2)
10. Release bracket with coolant heater assembly (1) (if installed) from
support frame
• Remove bolt (3)
Page 4 of 26
1 3
S 0012860
1 2
3 S 0012862
S 0013151
2 S 0012714
17. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
Page 9 of 26
S 0013060
18. Disconnect harness for oxygen sensor and turbocharger temperature sensor from engine harness
• Disconnect 2x harness connector
19. Release harness from 4x clip (3) on fuel rail cover, then move to one side
20. Disconnect breather hose from cylinder head cover
• Release 2x integral clip (2)
21. Remove fuel rail cover (1) from engine
• Release 4x clip
22. Install new blanking plug to cylinder head cover
23. Remove breather hose from turbocharger intake hose
• Pull off
Page 10 of 26
S 0012992
S 0013069
S 0013070
30. Disconnect fuel feed pipe (2) from high pressure pump
• Release 2x integral clip (1)
1 2
• Release from clip on engine
• Install 2x new blanking plug
31. Disconnect fuel leak-off pipe (3) from high pressure pump
3
• Release integral clip
• Install 2x new blanking plug
S 0012928
Install
1 2
S 0012928
41. Install upper section (4) of guide tube for oil level dipstick to lower
section
• Install new O ring seal
• Remove blanking plug
• Push into lower section of guide tube to secure to 2x clip
• Install bolt (2) 6 Nm
• Secure harness (1) to guide tube
42. Install oil level dipstick (3) to guide tube
Page 16 of 26
1 2 3
S 0013070
S 0012992
S 0013069
Page 18 of 26
52. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
S 0013060
Page 19 of 26
2 S 0012714
S 0013151
1 2
3 S 0012862
59. Secure bracket with coolant heater assembly (1) (if installed) to support
frame 2
• Install bolt (3)
60. Secure harness for coolant heater assembly (if installed) to support
frame 1 3
• Secure clip (2)
S 0012860
61. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
Page 24 of 26
1
2
3
S 0012861
1
1
S 0012753
63. Install air intake duct (1) to air cleaner assembly (2) and front panel
• Secure 2x clip
Page 25 of 26
S 0012752
S 0012749
1 2
S 0012751
J491020
Remove
1 2
3
S 0012762
8. Release power steering pump (2) from engine, then position to one side
Note: The power steering hoses are not disconnected; this avoids fluid
loss and eliminates the need to bleed the hydraulic system.
• Remove 3x bolt (1, 3)
Page 4 of 8
S 0012988
Install
S 0012988
1 2
3
S 0012762
14. Rotate tension roller clockwise, then lock into position using Locating Pin KM-6130
15. Install ribbed V-belt to engine
• Rotate tension roller clockwise, then remove Locating Pin KM-6130
(1)
Page 8 of 8
J491020
Remove
S 0012771
S 0012989
Install
Page 2 of 2
S 0012989
S 0012771
7. Install upper front panel – see operation “Upper Front Panel, Remove and Install or Replace”
8. Connect battery negative lead
9. Program all volatile memories
10. For vehicles as of MY 2008, program fuel pressure regulator using Tech 2
Page 1 of 1
G9U 632 (low G9U 630 and G9U G9U 650 (low G9U 650 (high
Engine
output) 632 (high output) output) output)
Bosch EDC 16
Engine management system - Bosch EDC 16 C36 Bosch EDC 16 C36 Bosch EDC 16 C36
C36
Exhaust emission standards - Euro IV Euro IV Euro IV Euro IV
No. of cylinders/configuration - 4 in line 4 in line 4 in line 4 in line
No. of valves - 16 16 16 16
Capacity cm 3 2463 2463 2463 2463
Bore diameter mm 89 89 89 89
Stroke mm 99 99 99 99
Firing order - 1–3–4–2 1–3–4–2 1–3–4–2 1–3–4–2
Power output kW/rpm 88/3500 107/3500 74/3500 88/3500
Torque Nm/rpm 300/1500 320/1500 260/1600 290/1600
J457500
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
2. Disconnect battery negative lead
3. Remove upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
4. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
1 2
• Release clip (2)
S 0012751
2
1
3
S 0012749
7. Remove air intake duct (1) from air cleaner assembly (2) and front panel
• Release 2x clip 2
S 0012752
1
1
S 0012753
9. Release harness (1) for mass air flow meter from support frame (2)
• Release clip (3)
1
2
3
S 0012861
10. Release harness for coolant heater assembly from support frame
• Release clip (2)
11. Release bracket with coolant heater assembly (1) from support frame
• Remove bolt (3)
Page 4 of 91
1 3
S 0012860
12. Remove support frame for air cleaner assembly from engine compartment
• Remove 2x nut
2 S 0014441
S 0012865
S 0012870
S 0012722
S 0013066
S 0012872
S 0012760
2
3
4 S 0016919
35. Release 2x harness (if installed) for 2x ABS sensor from subframe and 2x lower arm
• Release from 6x clip
• Release from 2x bracket
36. Raise vehicle
37. Release 2x brake pipe from subframe
• Release 2x clip
1 2 3 4
5
S 0012879
3
S 0012881
45. Remove subframe with steering gear and 2x lower arm from vehicle
Note: Illustration shows jack removed for clarity.
• Remove 2x bolt (1)
Page 12 of 91
46. Disconnect hose assembly (1) for differential pressure sensor from front
exhaust pipe (2), then move to one side 1
• Counterhold adapter and release union (3)
• Install 2x new blanking plug
2 S 0012883
2 S 0012884
S 0012885
50. Remove bracket (2), left side, from primary catalytic converter and
engine
• Remove 3x bolt (1)
• Release vacuum hose from clip on bracket
51. Remove bracket (3), right side from primary catalytic converter and
engine
• Remove 4x bolt (4)
Page 15 of 91
S 0012873
53. Remove 2x clip from 2x harness for oxygen sensor and turbocharger temperature sensor
54. Remove primary catalytic converter (1) from turbocharger
• Remove 4x nut (2), gasket 1
S 0012886
5
4
3 S 0012887
2
1
S 0012890
1 2
S 0012891
S 0012716
62. Install Positioning Pin KM-6203 (arrowed), through oil filter housing into
crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
Page 19 of 91
PMH
S 0017785
63. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
64. Lower vehicle
65. Release 2x fuel pipe (1) from bracket, then move to one side
• Release from 2x clip
Page 20 of 91
S 0012715
66. Remove bracket with upper engine stabiliser from engine compartment
• Remove 4x bolt (2), nut (1)
2 S 0012721
67. Remove bracket for intercooler hose assembly from upper cover for timing belt
• Remove 2x bolt
S 0012718
S 0012723
77. Remove timing belt (2) with intake camshaft pulley (1)
• Remove 3x bolt
80. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
Page 25 of 91
S 0013060
S 0013067
S 0013069
86. Disconnect pipe (1) from vacuum pump, then move to one side
• Release integral clip
• Install new blanking plug
2 S 0012969
1 2
S 0013073
91. Disconnect harness connector (1) EGR vacuum control solenoid (2)
2
1
S 0013074
94. Remove oil level dipstick (3) from guide tube (4)
95. Release harness from oil level dipstick guide tube
1 2 3
• Release from clip (1)
96. Remove upper section of guide tube (4) from engine
• Remove bolt (2)
• Release 2x clip
• Remove O ring
• Install new blanking plug
4
S 0013070
98. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side 1
• Release from clip on engine lifting eye
• Release 2x integral clip (2)
• Install 2x new blanking plug
2 S 0012995
101. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
102. Disconnect high pressure pipe (2) from high pressure pump
• Release pipe union (3)
– Use Pipe Spanner KM-812 ; counterhold nut on high
pressure pump using suitable spanner
• Install 2x new blanking plug
103. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Release integral clip
• Install 2x new blanking plug
Page 33 of 91
1 2
3 S 0013000
106. Remove high pressure pipe from common rail and cylinder head cover
• Release pipe union (1)
– Use Pipe Spanner KM-812
121. Remove support bracket for 2x fuel pipe from cylinder head cover
• Remove 2x screw (1)
Page 37 of 91
1 S 0013075
1 2 S 0006446
134. Check plane surface of cylinder head – see operation “Cylinder Head, Check for Plane Surface”
Install
Important: Remove all fluids from the threaded holes in the cylinder block
to ensure the correct tightening of the cylinder head bolts. Use a syringe to
remove any oil/coolant.
135. Install new cylinder head gasket to cylinder block
• Locate cylinder head gasket onto 2x dowel
Page 42 of 91
Important: Install 10x new cylinder head bolts. Do not lubricate cylinder
head bolts.
136. Install cylinder head to cylinder block
Note: 2x technician are required.
Note: Do not re-tighten cylinder head bolts after carrying out the
following procedure.
• Install 10x cylinder head bolt 30 Nm in sequence shown
• Check torque of 10x cylinder head bolt is 30 Nm in sequence
shown
• Secure 10x cylinder head bolt 300° ± 6° in sequence shown
Page 43 of 91
1 2 S 0006446
Important: Ensure that the flat surfaces (arrowed) on the end of the rocker
Page 44 of 91
146. Install 2x new rubber gasket, 7x new seal to cylinder head cover
• Clean all mating surfaces of cylinder head cover
155. Secure vacuum control valve with support bracket to cylinder head cover
• Install 3x screw
156. Install support bracket for 2x fuel pipe to cylinder head cover
• Install 2x screw (1)
Page 50 of 91
159. Install fuel rail protector (1) and gasket to cylinder head
• Clean mating surfaces, then apply suitable sealant – see
“Sealants, Lubricants and Locking Compounds”
• Install 2x bolt; do not tighten at this stage
• Secure grommet (2) to breather pipe connection
Page 51 of 91
S 0013077
172. Install 4x high pressure pipe to common rail and 4x fuel injector; do
not tighten at this stage
• Remove 16x blanking plug
173. Secure 4x high pressure pipe to common rail
• Secure 4x pipe union (1) 22 Nm
– Use Pipe Spanner KM-812
Page 54 of 91
S 0013082
179. Install high pressure pipe (1) to common rail; do not tighten at this
stage
• Remove 2x blanking plug
Page 56 of 91
• Secure to 3x clip
2 S 0012995
191. Install upper section of guide tube (4) for oil level dipstick to lower
section and engine 1 2 3
• Remove blanking plug
• Install new O ring
• Push into lower section of guide tube to secure to 2x clip
• Install bolt (2) 6 Nm
192. Secure harness to guide tube for oil level dipstick
• Secure clip (1)
193. Install oil level dipstick to guide tube
• Secure to clip (3)
4
S 0013070
195. Connect harness connector (1) to EGR vacuum control solenoid (2)
2
1
S 0013074
1 2
S 0013073
2 S 0012969
S 0013069
S 0013067
207. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
Page 65 of 91
S 0013060
210. Install new timing belt (2) with intake camshaft pulley (1)
• Install 3x bolt; do not tighten at this stage
Note: Ensure the timing belt locates centrally on the pulleys; the
camshaft pulleys locate correctly on the camshafts, and that the
bolts are in the centre of the slots.
Page 67 of 91
S 0012717
PMH
S 0017785
• Secure bolt
S 0012723
S 0012718
235. Install bracket for intercooler hose assembly to upper cover for timing belt
• Install 2x bolt 8 Nm
3
5 4 S 0013084
S 0012715
S 0012717
S 0012716
241. Remove Engine Support KM-6210-A – see operation “Engine Support KM-6210-A, Install and Remove”
242. Install turbocharger (1) to exhaust manifold (2)
• Clean mating surfaces 1 2
• Install new gasket, 3x new nut (3); do not tighten at this stage
S 0012891
2
1
S 0012890
S 0012886
S 0012873
252. Install bracket (2), left side, to primary catalytic converter and engine
• Install 3x bolt (1)
• Secure vacuum hose to clip on bracket
253. Install bracket (3), right side, to primary catalytic converter and engine
• Install 4x bolt (4)
Page 79 of 91
254. Install 2x clip to 2x harness for oxygen sensor and turbocharger temperature sensor
255. Install front exhaust pipe to diesel particulate filter
• Clean mating surfaces
• Install new gasket
• Install 2x new nut; do not tighten at this stage
256. Secure front exhaust pipe to primary catalytic converter
• Clean mating surfaces
• Install new gasket
• Install 2x new nut; do not tighten at this stage
257. Secure 4x nut 21 Nm
Page 80 of 91
S 0012885
258. Connect hose assembly (1) for differential pressure sensor to front
exhaust pipe (2)
• Remove 2x blanking plug
• Apply suitable sealant to hose assembly
• Counterhold adapter and secure union (3) 21 Nm
Page 81 of 91
2 S 0012883
2 S 0012884
260. Install subframe with steering gear and 2x lower arm to vehicle
Note: Illustration shows jack removed for clarity.
• Apply locking compound to 2x bolt – see “Sealants, Lubricants and
Locking Compounds”
• Install 2x bolt (1) 60 Nm
Page 82 of 91
261. For vehicles with additional heater, install reaction link, left side to
chassis
• Install bolt (1); do not tighten at this stage
1 2 3 4
5
S 0012879
1 2
3
S 0012881
2
3
4 S 0016919
272. Secure 2x harness (if installed) for 2x ABS sensor to subframe and 2x lower arm
• Secure to 6x clip
• Secure to 2x bracket
S 0012872
S 0013066
S 0012722
S 0012870
S 0012865
2 S 0014441
288. Install upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
289. Install support frame for air cleaner assembly to engine compartment
• Install 2x nut 8 Nm
290. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
1
2
3
S 0012861
291. Secure bracket with coolant heater assembly (1) (if installed) to
support frame
• Install bolt (3)
292. Secure harness for coolant heater assembly (if installed) to support
frame
• Secure clip (2)
Page 90 of 91
1 3
S 0012860
298. To prime turbocharger, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
299. Install engine immobiliser/instrument panel fuse to interior fuse box
300. Install left ashtray housing to instrument panel
• Secure 4x clip
301. Start engine, and run until the oil pressure indicator lamp is extinguished
302. Stop engine
303. Check engine oil level, top up if necessary
304. Raise vehicle
305. Install splash panel, right side
• Install 2x bolt 8 Nm , screw 6 Nm
• Secure washer hose (if installed) to 2x clip
J486000
Remove
1. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
S 0012749
4. Release air intake duct (1) from air cleaner assembly (2)
• Release 2x clip
Page 2 of 8
S 0012752
1
1
S 0012753
6. Release harness (1) for mass air flow meter from support frame (2)
• Release clip (3)
Page 3 of 8
1
2
3
S 0012861
7. Release harness for coolant heater assembly (1) from support frame
• Release clip (2)
8. Release bracket with coolant heater assembly from support frame
• Remove bolt (3)
2
1 3
S 0012860
Page 4 of 8
1 2
3 S 0012862
Install
1 2
3 S 0012862
15. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
Page 6 of 8
1
2
3
S 0012861
16. Secure bracket with coolant heater assembly (1) to support frame
• Install bolt (3)
17. Secure harness for coolant heater assembly to support frame
• Secure clip (2)
2
1 3
S 0012860
1
1
S 0012753
19. Secure air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
S 0012752
2
1
3
S 0012749
1 2
S 0012751
Page 1 of 5
J607320
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
3. Remove right splash panel
• Release washer hose from 2x clip
• Remove 2x bolt , screw
Install
J461400
Remove
S 0012751
S 0012749
5. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
Page 2 of 16
S 0012752
1
1
S 0012753
7. Release harness (1) for mass air flow meter from air cleaner support
frame (2)
• Release clip (3)
Page 3 of 16
1
2
3
S 0012861
8. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3) 1 2
• Release clip (2)
S 0012918
9. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Release clip (2)
• Remove bolt (3)
Page 4 of 16
1 3
S 0012860
1 2
3 S 0012862
S 0012741
2 S 0012714
18. Release lower section of guide tube for oil level dipstick from engine
• Remove bolt (1)
19. Release harness for EGR from lower section of guide tube
• Release clip
Page 8 of 16
S 0012906
S 0013070
Install
S 0012906
S 0013070
2 S 0012714
S 0012741
1 2
3 S 0012862
36. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
37. Install harness (1) for mass air flow meter to air cleaner support frame
(2) 1
• Secure clip (3)
2
3
S 0012861
38. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2)
Page 14 of 16
1 3
S 0012860
39. Secure coolant preheater harness (1) (if installed) to air cleaner support
frame (3) 1 2
• Secure clip (2)
S 0012918
1
1
S 0012753
41. Install air intake duct (1) to air cleaner (2) and vehicle body
• Secure 2x clip 2
S 0012752
2
1
3
S 0012749
S 0012751
J491030
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
2. Disconnect battery negative lead
3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
S 0012752
1
1
S 0012753
8. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
1 2
S 0012918
9. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Release clip (2)
• Remove bolt (3)
Page 4 of 26
1 3
S 0012860
1 2
3 S 0012862
S 0012741
2 S 0012714
S 0012865
17. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
S 0013065
S 0013066
S 0013067
25. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
Install
S 0009855
30. Connect high pressure pipe (1) to common rail; do not tighten at this
stage
• Remove 2x blanking plug
32. Install new high pressure pipe to common rail and high pressure pump
• Remove 4x blanking plug
• Connect 2x pipe union (1, 4); do not tighten at this stage
• Secure high pressure pipe to clip (3)
• Install bolt (2); do not tighten at this stage
33. Secure common rail to cylinder head
• Secure 2x bolt 25 Nm
34. Secure high pressure pipe to common rail and high pressure pump
• Secure 2x pipe union (1, 4) 27 Nm
Page 15 of 26
S 0013067
S 0013066
S 0013065
44. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
Page 19 of 26
S 0013060
S 0012865
2 S 0012714
S 0012741
1 2
3 S 0012862
50. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
51. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2) 2
• Push on 4x locating peg
1 3
S 0012860
52. Secure coolant preheater harness (1) (if installed) to air cleaner support
frame (3)
• Secure clip (2)
Page 24 of 26
1 2
S 0012918
1
1
S 0012753
54. Install air intake duct (1) to air cleaner (2) and vehicle body
• Secure 2x clip
Page 25 of 26
S 0012752
S 0012749
1 2
S 0012751
J491010
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
2. Disconnect battery negative lead
3. Remove upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
4. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
2
1
3
S 0012749
7. Remove air intake duct (1) from air cleaner assembly (2)
• Release 2x clip
S 0012752
1
1
S 0012753
9. Release harness (1) for mass air flow meter from support frame (2)
• Release clip (3)
1
2
3
S 0012861
10. Release harness for coolant heater assembly from support frame
• Release clip (2)
11. Release bracket with coolant heater assembly (1) from support frame
• Remove bolt (3)
Page 4 of 47
1 3
S 0012860
12. Remove support frame for air cleaner assembly from engine compartment
• Remove 2x nut
13. For vehicles with air conditioning, release pulley (1) from power
steering pump (2)
• Release 3x bolt (3); do not remove at this stage
1 2
3
S 0012762
17. For vehicles with air conditioning, remove ribbed V-belt from engine
• Rotate tension roller clockwise, then lock using Locating Pin KM-
6130 (1)
Page 6 of 47
18. For vehicles with air conditioning, rotate tension roller clockwise, then remove Locating Pin KM-6130
19. For vehicles with air conditioning, remove idler roller for ribbed V-belt
from engine
• Remove bolt (1)
Page 7 of 47
20. For vehicles with air conditioning, remove tensioner (1) for ribbed V-belt
from engine
• Remove 2x bolt (2)
S 0012716
22. Install Positioning Pin KM-6203 (arrowed), through oil filter housing into
crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
Page 9 of 47
PMH
S 0017785
26. For vehicles without air conditioning, release power steering feed hose
from auxiliary support bracket, then move to one side
• Pull off
Page 10 of 47
S 0012764
27. Remove bracket (1) from auxiliary support bracket and exhaust gas
recirculation (EGR) valve housing
• Remove 2x bolt (2)
• Release 2x harness from bracket
– Release 2x clip (3)
2
3 S 0012765
28. For vehicles with air conditioning, release power steering pump from
engine, then move to one side
• Remove 3x bolt
Page 11 of 47
S 0012766
29. Secure upper coolant hose for radiator to engine using suitable method
Note: To allow access to the EGR cooler.
30. Disconnect engine harness connector from EGR control solenoid
harness
Page 12 of 47
S 0013268
31. Release EGR cooler from intake manifold and EGR valve housing
• Disconnect vacuum hose
• Remove 7x bolt (1), then move to one side
• Remove gasket
S 0013422
33. Secure lower coolant hose for radiator to transmission, using suitable method
Note: To allow access to the EGR valve housing.
34. Remove EGR valve housing (2) with support bracket from engine
• Release clip (1)
• Disconnect 2x harness connector
• Remove 2x bolt (3)
1 2
S 0013423
• Remove O ring
1 2 3
S 0013070
37. Remove lower section of guide tube for oil level dipstick from engine
• Remove bolt (1)
• Withdraw lower section
• Install new blanking plug to engine
• Remove O ring
S 0012906
2 S 0012969
40. Release camshaft sensor from casing of high pressure pump, then
move to one side
Note: The harness connector is not disconnected.
• Remove bolt (1), O ring
S 0012908
Page 16 of 47
41. Disconnect harness for oxygen sensor and turbocharger temperature sensor from engine harness
• Disconnect 2x harness connector
42. Release harness from 4x clip (3) on fuel rail cover, then move to one side
43. Disconnect breather hose from cylinder head cover
• Release 2x integral clip (2)
44. Remove fuel rail cover (1) from engine
• Release 4x clip
45. Install new blanking plug to cylinder head cover
46. Remove breather hose from turbocharger intake hose
• Pull off
51. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
52. Release high pressure pipe from common rail and cylinder head cover
• Release pipe union (1)
– Use Pipe Spanner KM-812
53. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side
• Release from clip on engine lifting eye
• Release 2x integral clip (2)
• Install 2x new blanking plug
Page 19 of 47
2 S 0012995
54. Remove high pressure pipe (2) from high pressure pump
• Release pipe union (3)
– Use Pipe Spanner KM-812 ; counterhold nut on high pressure
pump using suitable spanner 1 2
• Install 2x new blanking plug
55. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Release integral clip
• Install 2x new blanking plug
3 S 0013000
Important: Ensure that the casing of the high pressure pump is not
damaged when removing blanking cover.
56. Remove blanking cover (1) from casing of high pressure pump
• Prise out using suitable tool
Page 20 of 47
S 0012929
57. Install Gear Puller KM-6207 (1) to casing of high pressure pump
Note: If gear puller cannot be installed, remove Positioning Pin KM-
6203 , rotate engine 360 degrees and reinstall positioning pin.
• Remove centre bolt (2) from Gear Puller KM-6207
• Install 4x bolt
S 0012717
S 0012716
S 0012931
Install
S 0012933
71. Install centre nut (1) to high pressure pump; do not tighten at this stage
Page 28 of 47
S 0012931
S 0012934
79. Install new fuel leak-off pipe (3) with fuel temperature sensor to high
pressure pump
• Remove 2x blanking plug
• Secure integral clip
Page 29 of 47
S 0012928
82. Install high pressure pipe to common rail and high pressure pump
• Remove 4x blanking plug
• Secure to clip
• Install bolt (2); do not tighten at this stage
• Connect 2x pipe union (1, 3); do not tighten at this stage
Page 30 of 47
S 0012934
Page 35 of 47
101. Install lower section of guide tube for oil level dipstick to engine
• Install new O ring
• Remove blanking plug from engine
• Install bolt (1) 25 Nm
S 0012906
S 0013070
S 0012908
2 S 0012969
108. Install EGR valve housing (2) with support bracket to engine
• Install 2x bolt (3) 25 Nm
• Secure clip (1)
• Connect 2x harness connector
Page 37 of 47
1 2
S 0013423
114. Secure EGR cooler to intake manifold and EGR valve housing
• Clean mating surfaces
• Install new gasket
• Install 7x bolt (1) 25 Nm
• Connect vacuum hose 1
S 0013422
S 0013268
S 0012766
118. Install bracket (1) to auxiliary support bracket and EGR valve housing
• Install 2x bolt (2) 15 Nm
• Secure 2x harness to bracket
– Secure 2x clip (3)
Page 40 of 47
3 S 0012765
119. For vehicles without air conditioning, secure power steering feed hose
to auxiliary support bracket
• Push on
S 0012764
120. For vehicles with air conditioning, install pulley (1) to power steering
pump (2)
• Install 3x bolt (3); do not tighten at this stage
Page 41 of 47
1 2
3
S 0012762
124. For vehicles with air conditioning, install new tensioner (1) for ribbed
V-belt to engine
• Install 2x bolt (2) 21 Nm
Page 42 of 47
125. For vehicles with air conditioning, install ribbed new V-belt to engine
• Rotate tension roller clockwise, then remove Locating Pin KM-
6031 (1)
Page 43 of 47
3
S 0012762
130. Install support frame for air cleaner assembly to engine compartment
• Install 2x nut 8 Nm
131. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
Page 45 of 47
1
2
3
S 0012861
132. Secure bracket with coolant heater assembly (1) (if installed) to
support frame
• Install bolt (3)
133. Secure harness for coolant heater assembly (if installed) to support
2
frame
• Secure clip (2)
1 3
S 0012860
1
1
S 0012753
135. Secure air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
S 0012752
136. Connect harness connector (3) to mass air flow meter (1)
137. Connect hose (2) to mass air flow meter
• Secure clip
Page 47 of 47
2
1
3
S 0012749
1 2
S 0012751
139. Install upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
140. Connect battery negative lead
141. Program all volatile memories
142. Program fuel pressure regulator using Tech 2 (if required)
Note: Tech 2 programming may be required depending on the evolution of the new high pressure pump supplied.
Page 1 of 58
J471500
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
2. Disconnect battery negative lead
3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
1 2
• Release clip (2)
S 0012751
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip 2
S 0012752
1
1
S 0012753
8. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
1
2
3
S 0012861
9. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
Page 4 of 58
1 2
S 0012918
10. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame 2
• Release clip (2)
• Remove bolt (3)
1 3
S 0012860
Page 5 of 58
1 2
3 S 0012862
S 0012741
2 S 0012714
S 0012865
18. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
S 0013065
S 0013066
S 0013067
S 0012872
S 0012873
26. Release fuel rail protector drain hose from engine assembly
• Release 2x clip
27. Disconnect harness connector from exhaust gas recirculation (EGR) module
28. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
29. Lower vehicle
30. Release fluid reservoir for power steering from upper front panel
• Release clip, then pull upwards
31. Remove oil level dipstick (3) from guide tube (4)
32. Release harness from oil level dipstick guide tube
• Release from clip (1)
33. Remove upper section of guide tube (4) from engine
• Remove bolt (2)
• Release 2x clip
• Remove O ring
Page 13 of 58
S 0013070
S 0013069
2 S 0012969
1 2
S 0013073
42. Disconnect harness connector (1) from EGR vacuum control solenoid
(2) 2
1
S 0013074
43. Release engine harness cover from intake manifold, then move to side
• Remove screw (1)
Page 17 of 58
45. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side
• Release from clip on engine lifting eye
• Release 2x integral clip (2)
• Install 2x new blanking plug
Page 18 of 58
2 S 0012995
48. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
49. Disconnect high pressure pipe (2) from high pressure pump
• Release pipe union (3) 1 2
– Use Pipe Spanner KM-812 ; counterhold nut on high pressure
pump using suitable spanner
• Install 2x new blanking plug
50. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Release integral clip
• Install 2x new blanking plug
3 S 0013000
53. Remove high pressure pipe from common rail and cylinder head cover
• Release pipe union (1)
– Use Pipe Spanner KM-812
65. Remove fuel rail protector (1) and gasket from cylinder head
• Remove 2x bolt
• Release grommet (2) from breather pipe connection
Page 23 of 58
68. Remove support bracket for 2x fuel pipe from cylinder head cover
• Remove 2x screw (1)
70. Release 2x fuel pipe (1) from engine mount, then move to one side
• Release from 2x clip
1
S 0012715
71. Remove engine mount with torque reaction link from engine and vehicle
body
• Remove 4x bolt (2), nut (1)
Page 25 of 58
2 S 0012721
1 S 0013075
Install
78. Install 2x new rubber gasket, 7x new seal to cylinder head cover
• Clean all mating surfaces of cylinder head cover
Page 28 of 58
87. Install engine mount with torque reaction link to engine and vehicle
body
• Install 4x bolt (2), new nut (1); do not tighten at this stage
2 S 0012721
3 S 0012724
S 0012715
93. Secure vacuum control valve with support bracket to cylinder head cover
• Install 3x screw
94. Install support bracket for 2x fuel pipe to cylinder head cover
• Install 2x screw (1)
Page 34 of 58
97. Install fuel rail protector (1) and gasket to cylinder head
• Clean mating surfaces, then apply suitable sealant – see “Sealants,
Lubricants and Locking Compounds”
• Position drain hose to rear of engine
• Install 2x bolt; do not tighten at this stage
• Secure grommet (2) to breather pipe connection
Page 35 of 58
S 0013077
110. Install 4x high pressure pipe to common rail and 4x fuel injector; do
not tighten at this stage
• Remove 16x blanking plug
111. Secure 4x high pressure pipe to common rail
• Secure 4x pipe union (1) 22 Nm
– Use Pipe Spanner KM-812
Page 38 of 58
S 0013082
117. Install high pressure pipe (1) to common rail; do not tighten at this
stage
• Remove 2x blanking plug
Page 40 of 58
• Secure to 3x clip
2 S 0012995
129. Install upper section of guide tube (4) for oil level dipstick to lower
section and engine 1 2 3
• Remove blanking plug
• Install new O ring
• Push into lower section of guide tube to secure to 2x clip
• Install bolt (2) 6 Nm
130. Secure harness to guide tube for oil level dipstick
• Secure clip (1)
131. Install oil level dipstick to guide tube
• Secure to clip (3)
4
S 0013070
133. Connect harness connector (1) to EGR vacuum control solenoid (2)
2
1
S 0013074
1 2
S 0013073
2 S 0012969
S 0013069
142. Secure power steering reservoir and support bracket to upper front panel
• Secure to clip
143. Raise vehicle
144. Remove Engine Support KM-6210-A from vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
145. Connect harness connector to EGR module
146. Secure fuel rail protector drain hose to engine assembly
• Secure 2x clip
S 0012873
S 0012872
S 0013067
S 0013066
S 0013065
154. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
S 0013060
S 0012865
2 S 0012714
S 0012741
1 2
3 S 0012862
160. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
161. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
1
2
3
S 0012861
162. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2)
Page 56 of 58
1 3
S 0012860
163. Secure coolant preheater harness (1) (if installed) to air cleaner
support frame (3) 1 2
• Secure clip (2)
S 0012918
1
1
S 0012753
165. Install air intake duct (1) to air cleaner (2) and vehicle body
• Secure 2x clip 2
S 0012752
2
1
3
S 0012749
S 0012751
Intercooler, Replace
J600400
Remove
1. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
S 0012749
S 0012752
1
1
S 0012753
6. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
Page 3 of 15
1
2
3
S 0012861
7. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
1 2
S 0012918
8. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Release clip (2)
• Remove bolt (3)
Page 4 of 15
1 3
S 0012860
S 0012741
Page 5 of 15
1 2
3 S 0012862
S 0014169
S 0014170
Install
S 0014170
S 0014169
1 2
3 S 0012862
19. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
S 0012741
21. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
1
2
3
S 0012861
22. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2)
Page 13 of 15
1 3
S 0012860
1
1
S 0012753
S 0012752
S 0012749
1 2
S 0012751
Page 1 of 2
J741000
Remove
1. Remove mass air flow meter (2) from cover (1) of air cleaner assembly
• Disconnect harness connector (4) from mass air flow meter
• Release harness for mass air flow meter from air cleaner assembly
– Release from clip
• Disconnect hose (3) from mass air flow meter, then move to one side
– Release clamp
2. Remove mass air flow meter from cover of air cleaner assembly
• Remove 2x screw
Install
3. Install new mass air flow meter (2) to cover (1) of air cleaner assembly
• Install 2x screw
4. Connect hose (3) to mass air flow meter
• Secure clamp
Page 2 of 2
• Secure harness for mass air flow meter to air cleaner assembly
– Secure to clip
• Connect harness connector (4) to mass air flow meter
Page 1 of 1
1. Oil consumption for a combustion engine refers to the amount of oil consumed as a result of the combustion process. Oil consumption
is not to be equated with oil loss resulting from leaks from components such as the oil pan and cylinder head cover.
The role of engine oil is to:
1. separate surfaces that slide against each other by means of an oil film, i.e. to prevent dry friction
2. dissipate heat generated by friction
3. lead away combustion residue
These tasks lead to a certain amount of oil consumption. Thus, the expectation that further development of the combustion engine will
eventually mean that engines will not consume any oil is wrong.
Outside operating conditions, driving style and manufacturing tolerances do, however, have an impact on oil consumption.
It is imperative that oil be filled when the level has fallen below the "MIN" mark on the dipstick.
It is also important to ensure that the oil level is not above the "MAX" mark on the dipstick as this could result in increased oil
consumption.
As oil consumption is affected by technical factors, the conclusion is reached that the engine does not consume oil in special operating
conditions that lead to oil dilution.
During conditions such as frequent cold starts and driving before the engine reaches operating temperature, it is only the oil flowing
back to the oil pan that carries away scalding fuel components and precipitates. This "dilutes" the oil and leads to the erroneous
assumption that the engine consumes no oil.
Such diluted oil loses its ability to lubricate and could cause engine damage if the prescribed oil change intervals are not observed.
Driving in predominately urban traffic and frequently running a cold engine at rpm above idle speed are the main causes of oil dilution.
As oil consumption does not stabilise until after a few thousand kilometres of travel, oil consumption measurements are not reliable until
after a distance of about 7,500 km.
Before measuring consumption, ensure that the engine is not losing oil due to leakage.
The oil dipstick can only be used to check oil level. It cannot be used for measurement. The engine must have been off at least 10
minutes, (for F9Q engines 15 minutes) before checking oil level. If after an engine oil change the maximum oil capacity does not match
the maximum level of the dipstick, this is due to necessary manufacturing tolerances.
All information on permissible engine oil consumption and capacities are found in the Owner's Manual.
1. The check is carried out with the vehicle parked on a level surface with the engine at operating temperature (engine oil
temperature at least 80°C).
2. Drain the engine oil immediately after switching off the engine - drainage time = approximately 30 minutes (this value has been
obtain through technical trials).
3. The quantity of drained engine oil is determined via a measuring container. The container is then filled with fresh oil up to the
maximum engine oil capacity minus the volume remaining in the unchanged oil filter.
4. With this engine oil quantity, the customer should be able to travel at 1000 km without needing to top up engine oil (the distance
profile and customer driving style should be maintained).
5. Then, the preceding procedure (points 1 and 2) should be repeated with the exact same engine drainage time.
6. The oil quantity now "missing" from the measuring container is equal to the engine oil consumption for that distance.
7. Oil consumption is calculated as follows:
filled oil quantity (l) – drained oil quantity (l) x 1000 = oil consumption (l/1000 km) total distance driven (km)
See table below.
Vehicle 1 to 2 litres 6 litres 7.5 litres
S8U 772, S9W 700, S9W 702, F9Q 770, F9Q
772, F9Q 774, G9T 720, G9T 722, G9U 720,
Movano
G9U 724, G9T 750, G9U 750, G9U 754, G9U
632, G9U 650, ZD3 200, ZD3 202
F4R 720, F4R 820, F9Q 760, F9Q 762, G9U
Vivaro 730, G9U 630, M9R 630, M9R 692, M9R 780,
M9R 782, M9R 784, M9R 786, M9R 788
Page 1 of 5
J460400
Remove
8. For vehicles with air conditioning, release power steering pipe assembly
(3) from oil cooler housing (2)
1 2
• Remove bolt
9. Disconnect harness connector (1) from oil pressure switch
3 S 0014335
S 0014336
Install
1 2
S 0014336
12. For vehicles with air conditioning, secure power steering pipe assembly
(3) to oil cooler housing (2) 1 2
• Install bolt
13. Connect harness connector (1) to oil pressure switch
3 S 0014335
21. To prime oil filter and cooler housing, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
22. Install engine immobiliser/instrument panel fuse to interior fuse box
23. Install left ashtray housing to instrument panel
• Secure 4x clip
24. Start engine, and run until the oil pressure indicator lamp is extinguished
25. Stop engine
26. Check engine oil level, top up if necessary
27. Raise vehicle
28. Install radiator undershield to support frame
• Install bolt (2), 2x screw (1)
Page 5 of 5
J456500
Remove
Install
14. Secure pressure hose of power steering to support bracket for engine
speed sensor
• Install nut (1)
Remove
1. Remove engine and transmission from vehicle – see operation “Engine and Transmission, Remove and Install”
• G9U 630
• G9U 730
2. Remove timing gear case from engine – see operation “Timing Gear Case, Replace”
3. Remove drive chain (1) with crankshaft sprocket (2) from crankshaft (3)
and oil pump sprocket (4)
5. Remove drive chain (1) with gear and oil deflector (2) from crankshaft (3)
Page 2 of 4
• Slide off
Install
6. Install new oil deflector (3) to new gear (4) using Installer KM-6296 (5)
• Position Installer KM-6296 into suitable vice
• Install gear into Installer KM-6296
• Install oil deflector onto gear, then position cover (2) above
• Rotate bolt (1) clockwise until oil deflector fully installed
– Remove Installer KM-6296 from gear and oil deflector
7. Install new drive chain (1) with gear and oil deflector (2) to crankshaft (3)
• Push fit
Page 3 of 4
10. Install timing gear case to engine – see operation “Timing Gear Case, Replace”
11. Install engine and transmission to vehicle – see operation “Engine and Transmission, Remove and Install”
• G9U 630
• G9U 730
J456600
Remove
1. Remove oil pan from engine – see operation “Oil Pan, Replace”
2. Remove oil pump (1) from cylinder block
• Remove 4x bolt (2)
• Release oil pump sprocket from chain
Install
8. For G9U730 engine, remove engine immobiliser/instrument panel fuse from interior fuse box
• Remove left ashtray housing from instrument panel
– Release 4x clip
9. To prime oil pump, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
10. Install engine immobiliser/instrument panel fuse to interior fuse box
11. Install left ashtray housing to instrument panel
• Secure 4x clip
12. Start engine, and run until the oil pressure indicator lamp is extinguished
13. Stop engine
14. Raise vehicle
15. Check for oil leaks
16. Lower vehicle
17. Check engine oil level, top up if necessary
Page 1 of 5
J456600
Remove
S 0014635
3 S 0014636
Install
2
1
3 S 0014636
S 0014635
S 0014219
21. To prime oil circuit, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
22. Install engine immobiliser/instrument panel fuse to interior fuse box
23. Install left ashtray housing to instrument panel
• Secure 4x clip
24. Check engine oil level, top up if necessary
Page 1 of 3
J463520
Remove
Install
6. Install Seal Installer KM-6424-2 (1) and seal (2) to intermediate shaft
gear
7. Install seal to intermediate shaft gear and ancillary drive housing
• Install Seal Installer KM-6299 (3) to Seal Installer KM-6424-2
– Install stud of Seal Installer KM-6299 through centre of
intermediate shaft gear
– Install nut (4) of Seal Installer KM-6299 to stud
• Turn nut (4) clockwise, until seal is fully installed to intermediate
shaft gear and ancillary drive housing
12. Install new timing belt – see operation ”Timing Belt, Replace”
• G9U 630
• G9U 730
13. Check and adjust oil level if necessary
J980400
Remove
1. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
S 0012749
S 0012752
1
1
S 0012753
6. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
Page 3 of 16
1
2
3
S 0012861
7. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3) 1 2
• Release clip (2)
S 0012918
8. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Release clip (2)
• Remove bolt (3)
Page 4 of 16
1 3
S 0012860
1 2
3 S 0012862
2 S 0012714
S 0013065
S 0013066
S 0012865
S 0012872
S 0012873
S 0012927
Install
22. Install new oxygen sensor (2) to primary catalytic converter, using
Socket KM-6179
• Apply assembly paste to threads – see “Sealants, Lubricants and
Locking Compounds”
23. Install temperature sensor to turbocharger
• Apply assembly paste to threads – see “Sealants, Lubricants and
Locking Compounds”
• Secure union (1)
Page 9 of 16
S 0012927
S 0012873
S 0012872
S 0013066
S 0013065
S 0012865
2 S 0012714
Page 13 of 16
1 2
3 S 0012862
34. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
1
2
3
S 0012861
35. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2)
Page 14 of 16
1 3
S 0012860
36. Secure coolant preheater harness (1) (if installed) to air cleaner support
frame (3) 1 2
• Secure clip (2)
S 0012918
1
1
S 0012753
S 0012752
2
1
3
S 0012749
S 0012751
Page 1 of 1
F9Q engine
G9 engine
Measure
Disassemble
Important: Take care not to damage piston skirt during piston ring replacement.
1. Remove piston with con-rod from engine
2. Install piston with con-rod to soft-jawed vice
3. Remove 3x piston ring from piston (4)
• Remove squared ring (1), tapered ring (2), then
oil control ring (3), in that order
– Use piston ring pliers (5) (commercially
available)
• Thoroughly clean location groove for each piston
ring
– Use removed piston ring as scraper
– G9U 730
Page 2 of 3
– G9U 730
Assemble
L502930
Remove
1. Raise vehicle
2. Disconnect primary temperature sensor from body harness
• Disconnect harness connector (1)
• Release from clip (2), then slide off
1
2 S 0012884
S 0014337
Install
S 0014337
2 S 0012884
6. Lower vehicle
Page 1 of 5
J606800
Remove
5. Lower vehicle
6. Remove upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
7. Release harness from cooling fan support housing
Page 2 of 5
S 0012835
10. Remove cooling fan motor (1) from cooling fan support housing
• Remove 3x bolt (2)
Page 3 of 5
Install
11. Install new cooling fan motor (1) to cooling fan support housing
• Install 3x bolt (2)
S 0012835
Radiator, Replace
J600500
Remove
9. Lower vehicle
10. Remove upper front panel – see operation ”Upper Front Panel, Remove and Install or Replace”
11. Remove air deflector from vehicle
• Release 2x clip (1)
• Release from locator
Page 3 of 13
Install
Remove
1. If replacing fuel injectors, download data from engine control unit using Tech 2 (For vehicles with SPS function).
Note: Vehicles with IMA injectors, record IMA injector code with Tech 2 for reprogramming.
S 0018298
S 0018299
1
S 0013310
Important: After installation the fuel injectors must be calibrated with their corrective values to ensure precise fuel flow.
14. If replacing fuel injectors, program engine control unit using Tech 2 (For vehicles with SPS function).
Page 1 of 2
J607000
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
3. Remove splash panel, right side
• Release washer hose (if installed) from 2x clip
• Remove 2x bolt , screw
Install
Page 2 of 2
J456100
Remove
1. Remove clutch assembly from flywheel – see operation “Clutch Assembly, Replace”
• G9U 630, G9U 730 without self-adjusting clutch
• G9U 730 with self-adjusting clutch
Install
3 4
S 0016510
S 0012716
9. Install Positioning Pin KM-6203 (arrowed), through oil filter housing into
crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
Page 5 of 10
PMH
S 0017785
S 0013137
12. Remove crankshaft inductive pulse pick-up (2) from cylinder block
• Depress spring clip (1), then withdraw from aperture in spring clip
and cylinder block
Page 7 of 10
S 0013138
13. Install Flywheel Positioning Tool KM-6403 (1) to cylinder block and
flywheel
• Push fit
– Move flywheel as necessary to ensure full location of
positioning tool
S 0012717
S 0012716
S 0013138
S 0013137
21. Install clutch assembly to flywheel – see operation “Clutch Assembly, Replace”
• G9U 630, G9U 730 without self-adjusting clutch
• G9U 730 with self-adjusting clutch
Page 1 of 2
L502920
Remove
1. Raise vehicle
2. Disconnect secondary temperature sensor from body harness
• Disconnect harness connector (1)
• Release from clip (2), then slide off
1
2 S 0014338
2 S 0014339
Install
2 S 0014339
2 S 0014338
6. Lower vehicle
Page 1 of 2
J496030
Remove
Install
7. For vehicles with F4R 820 engine, program pedal position sensor using Tech 2.
Page 1 of 6
J740500
Remove
S 0012751
S 0012749
5. Remove air intake duct (1) from air cleaner assembly (2)
• Release 2x clip
Page 2 of 6
S 0012752
1
1
S 0012753
Install
1
1
S 0012753
14. Install air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
S 0012752
2
1
3
S 0012749
1 2
S 0012751
Page 1 of 35
J491050
Remove
Warning: The diesel common rail system is under very high pressure (up to 1600 bar). Damage or personal injury may result if the safety
procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are
not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" .
Do not loosen or remove fuel lines when the engine is running.
As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from
penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect
in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently
(approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
2. Disconnect battery negative lead
3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
2
1
3
S 0012749
6. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
S 0012752
1
1
S 0012753
8. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
1
2
3
S 0012861
9. Release coolant preheater harness (1) (if installed) from air cleaner
support frame (3)
• Release clip (2)
Page 4 of 35
1 2
S 0012918
10. Release coolant preheater and bracket (1) (if installed) from air cleaner
support frame
• Release clip (2)
• Remove bolt (3) 2
1 3
S 0012860
Page 5 of 35
1 2
3 S 0012862
S 0012741
2 S 0012714
S 0012865
18. Remove oil filler hose with adapter from cylinder head cover
• Rotate anti-clockwise, then pull off
S 0013060
S 0013065
S 0013066
S 0013067
S 0012992
S 0013069
26. Remove oil level dipstick (3) from guide tube (4)
27. Release harness from oil level dipstick guide tube
• Release from clip (1)
28. Remove upper section of guide tube (4) from engine
• Remove bolt (2)
• Release 2x clip
• Remove O ring
• Install new blanking plug
Page 13 of 35
1 2 3
S 0013070
30. Disconnect fuel feed pipe (1) from high pressure pump, then move to
one side
• Release from clip on engine lifting eye
• Release 2x integral clip (2)
• Install 2x new blanking plug
Page 14 of 35
2 S 0012995
33. Release fuel leak-off pipe from cylinder head cover, then move to one side
• Release 3x clip
34. Disconnect high pressure pipe (2) from high pressure pump
• Release pipe union (3)
– Use Pipe Spanner KM-812 ; counterhold nut on high pressure
pump using suitable spanner 1 2
• Install 2x new blanking plug
35. Remove fuel leak-off pipe (1) with fuel temperature sensor from high
pressure pump
• Release integral clip
• Install 2x new blanking plug
3 S 0013000
38. Remove high pressure pipe from common rail and cylinder head cover
• Release pipe union (1)
– Use Pipe Spanner KM-812
Install
45. Install 4x high pressure pipe (1) to common rail and 4x fuel injector; do
not tighten at this stage
• Remove 16x blanking plug
46. Secure 4x high pressure pipe to common rail
• Secure 4x pipe union 22 Nm
– Use Pipe Spanner KM-812
Page 19 of 35
S 0009855
51. Install high pressure pipe (1) to common rail; do not tighten at this stage
• Remove 2x blanking plug
Page 21 of 35
56. Install new fuel leak-off pipe with fuel temperature sensor to high pressure pump
• Remove 2x blanking plug
• Secure integral clip
57. Connect fuel leak-off pipe to common rail
• Remove 2x blanking plug
• Secure 2x integral clip
2 S 0012995
62. Install upper section of guide tube (4) for oil level dipstick to lower
section and engine
• Remove blanking plug
• Install new O ring 1 2 3
• Push into lower section of guide tube to secure to 2x clip
• Install bolt (2) 6 Nm
63. Secure harness to guide tube for oil level dipstick
• Secure clip (1)
64. Install oil level dipstick to guide tube 4
• Secure to clip (3)
S 0013070
S 0013069
S 0012992
S 0013067
S 0013066
S 0013065
72. Install oil filler hose with adapter to cylinder head cover
• Push on, then rotate clockwise
Page 28 of 35
S 0013060
S 0012865
2 S 0012714
S 0012741
1 2
3 S 0012862
78. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
79. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
1
2
3
S 0012861
80. Secure coolant preheater and bracket (1) (if installed) to air cleaner
support frame
• Install bolt (3)
• Secure clip (2)
Page 33 of 35
1 3
S 0012860
81. Secure coolant preheater harness (1) (if installed) to air cleaner support
frame (3)
• Secure clip (2)
1 2
S 0012918
1
1
S 0012753
83. Install air intake duct (1) to air cleaner (2) and vehicle body
• Secure 2x clip
S 0012752
2
1
3
S 0012749
1 2
S 0012751
30
FLB FL4
60A 15 15
175A 323
15A 15A
30
224
FLA FLD 1P
RD 7
YE 5
YE 5
YE 5
YE 5
40A 40A
.1 .2
B1 A2 A1
40A 40A
30 15 15A
FLU St A M D FC27 FC28 FC29 BCM1 BCM5 BCM1 FC7
A B
RD 3
RD 3
30
10A 25A 10A FC6 10A
15 FC30 FC31
15A 30A
15A 15A
50
FB6 X4 50
S1
RD 4
RD 4
20A B2
A1
YE 1.5
YE 1/3
YE 1.5
YE 1.5
YE 2
YE 4
YE 3
WH 3
RD 3
A1
YE 0.5
YE 2.5
RD 7
2903
YE 2
3003
FC9 FC10 FC11 MTA MTA FC7
10A
MTA 10A 30A 15A 144 X7 X1
WH 4
WH 4
YE 2.5
2816 G9U630 87 86 1501 INS
RD 2
RD 2
5A
5402 ZH
RD 1.5
30 85
K24 M9R780
5503 BCM1 5505 BCM1 3 2
5531 BCM5 5533 BCM5
2508 X1
4830 EMP
G9U630 A8 5007 CID
YE 0.5/0.75
2707
G9U630
G9U630
RD 0.5
BG 0.5
GY 0.5
VT 0.5
RD 40
RD 25
M9R780
M9R780
M9R780
G9U630
G9U630
MTA
F9Q760
F4R820
+ B2 30 50
1518 INS
2704 G9U630
3303 IMO 30 50
3333 CDL
G1 3934 ESP
RD 0.5
- B+ 2 1
5512 BCM1
B+ F L
5540 BCM5
M G
2208 F4R820
31 31 B-
2411 F9Q760 M1 G2
2615 M9R780 31
2814 G9U630 FI D
BK 16/25
BK 25/40
11 16 16
Systems
STA+CHA Start & Charging VOLT Voltage distribution
Components
FB6 Fuse FLA Main fuse
FB7 Fuse FLB Main fuse
FC6 Fuse FLC Main fuse
FC7 Fuse FLD Main fuse
FC9 Fuse FLU Fuse unit - Main fuse
FC10 Fuse FLU.1 Main fuse
FC11 Fuse FLU.2 Main fuse
FC27 Fuse G1 Battery
FC28 Fuse G2 Alternator
FC29 Fuse K24 Relay - Starter
FC30 Fuse M1 Starter
FC31 Fuse S1 Switch - Starter
Connectors
X1 Instrument panel & Engine X7 Instrument panel & Extension harness, radio
X4 Instrument panel & Chassis X102 Engine & Extension harness, starter
Grounding Points
11 Crossmember, below vehicle 16 Battery
Abbreviations
10A 10 Ampere F9Q760 Engine F9Q 760
15 Ignition voltage FC7 Fuse FC7
30 Constant voltage FI Petrol
60A 60A FL4 Main fuse FL4
ABS Anti-Lock Brake System G9U630 Engine G9U 630
AC Air conditioning HZG Heating
ACS Accessory socket IMO Immobiliser
BCM1 Body control module 2001 INS Instrument
BCM5 Body control module 2005 M9R780 Engine M9R 780
CDL Central door locking MTA Manual transmission automatically shifted
CID Color Info Display STA Start & Charging
D Diesel TEL Telephone
DIAG Diagnostic link TFL Daytime running light
EMP Radio WI Wiper
ESP Electronic stability program ZH Add-on heater, fuel fired
F4R820 Engine F4R 820 ZIG Cigarette lighter
Color codes
Page 3 of 3
BG Beige RD Red
BK Black VT Violet
GY Gray WH White
L Light YE Yellow
OG Orange
Page 1 of 3
Starter, Replace
J700100
S 0012741
3. Raise vehicle
4. Remove engine and transmission undershield from vehicle
• Remove 8x bolt
3 2 S 0014185
Install
3 2 S 0014185
S 0012741
N318500
Remove
4. Remove oil pressure switch (1) from oil filter housing (2) 1 2
• Place collecting container below
• Disconnect harness connector
S 0013032
Install
5. Install new oil pressure switch (1) 20 Nm to oil filter housing (2)
• Install new seal ring to oil pressure switch
1 2
• Connect harness connector
S 0013032
Page 2 of 2
J607300
Remove
1. Raise vehicle
2. Remove engine and transmission undershield from vehicle
3. Remove right splash panel
• Release washer hose from 2x clip
• Remove 2x bolt , screw
Install
8. Rotate tension roller clockwise, then lock into position using suitable locating pin
9. Install ribbed V-belt to engine
• Rotate tension roller clockwise, then remove Locating Pin KM-6130
(1)
Page 4 of 5
J608500
Remove
Important: Observe the relevant environmental regulations when disposing of used coolant.
8. Drain cooling system
• Place collecting container below
• Open radiator drain plug
• Allow coolant to drain into collecting container
9. Disconnect hose (1) from oil filler on air cleaner assembly, then move to
one side
• Release clip (2)
1 2
S 0012751
10. Disconnect hose (2) from mass air flow meter (1)
• Release clip
11. Disconnect harness connector (3) from mass air flow meter
2
1
3
S 0012749
12. Remove air intake duct (1) from air cleaner (2) and vehicle body
• Release 2x clip
Page 3 of 13
S 0012752
1
1
S 0012753
14. Release air flow meter harness (1) from air cleaner support frame (2)
• Release clip (3)
Page 4 of 13
1
2
3
S 0012861
15. Release coolant heater assembly harness (1) (if installed) from air
cleaner support frame (3)
• Release clip (2)
1 2
S 0012918
16. Release coolant heater assembly and bracket (1) (if installed) from air
cleaner support frame
• Release clip (2)
• Remove bolt (3)
Page 5 of 13
1 3
S 0012860
1 2
3 S 0012862
S 0012865
S 0012870
Page 7 of 13
1 2
S 0006887
1 2 S 0006446
Install
1 2 S 0006446
1 2
S 0006887
S 0012870
S 0012865
1 2
3 S 0012862
37. Install air cleaner assembly support frame (1) to engine compartment
• Install 2x bolt (3), 2x nut (2)
38. Install air flow meter harness (1) to air cleaner support frame (2)
• Secure clip (3)
Page 11 of 13
1
2
3
S 0012861
39. Secure coolant heater assembly and bracket (1) (if installed) to air
cleaner support frame
• Install bolt (3)
• Secure clip (2) 2
1 3
S 0012860
40. Secure coolant heater assembly harness (1) (if installed) to air cleaner
support frame (3)
• Secure clip (2)
Page 12 of 13
1 2
S 0012918
J462400
Remove
S 0012716
Page 2 of 22
6. Install Positioning Pin KM-6203 (arrowed), through oil filter housing into
crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
PMH
S 0017785
7. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
8. Lower vehicle
9. Remove hose assembly from intercooler and turbocharger
• Release 2x clip (1)
• Remove bolt (2)
10. Remove O ring from hose assembly
Page 3 of 22
2 S 0012714
11. Release 2x fuel pipe (1) from bracket, then move to one side
• Release from 2x clip
Page 4 of 22
S 0012715
12. Remove bracket with upper engine stabiliser from engine compartment
• Remove 4x bolt (2), nut (1)
2 S 0012721
13. Remove bracket for intercooler hose assembly from upper cover for timing belt
• Remove 2x bolt
S 0012722
S 0012718
S 0012723
24. Remove timing belt (2) with intake camshaft pulley (1)
• Remove 3x bolt
Page 8 of 22
Install
29. Install new timing belt (2) with intake camshaft pulley (1)
• Install 3x bolt; do not tighten at this stage
Note: Ensure the timing belt locates centrally on the pulleys; the
camshaft pulleys locate correctly on the camshafts, and that the
bolts are in the centre of the slots.
Page 11 of 22
S 0012717
PMH
S 0017785
• Secure bolt
S 0012723
S 0012718
S 0012722
55. Install bracket for intercooler hose assembly to upper cover for timing belt
• Install 2x bolt 8 Nm
2
1
3
5 4 S 0013084
S 0012715
2 S 0012714
S 0012717
S 0012716
63. Remove Engine Support KM-6210-A – see operation “Engine Support KM-6210-A, Install and Remove”
64. Install right splash panel
• Install 2x bolt 8 Nm , screw 6 Nm
• Secure washer hose (if installed) to 2x clip
Page 22 of 22
J463040
Remove
1. Remove engine and transmission from vehicle – see operation “Engine with Transmission, Remove and Install”
• G9U 630
• G9U 730
3. For G9U 630, release high pressure pipe from auxiliary support bracket
• Remove bolt
4. For G9U 630, disconnect high pressure pipe (1) from power steering
pump
• Release union (2)
– Use Pipe Spanner KM-812
• Remove O ring
• Install 2x new blanking plug
Page 2 of 60
5. For G9U 630, remove power steering pipe assembly with fluid reservoir from engine and transmission assembly
• Remove 4x bolt
6. Remove bracket (2), left side, from primary catalytic converter and
engine
• Remove 3x bolt (1)
• Release vacuum hose from clip on bracket
7. Remove bracket (3), right side, from primary catalytic converter and
engine
• Remove 4x bolt (4)
S 0012886
2 S 0016489
13. For G9U 630, remove bracket (1) from turbocharger and engine
• Remove 2x bolt (2)
2
1
S 0012890
14. For G9U 730, remove exhaust heat shield from exhaust manifold
• Remove 3x bolt (1)
Page 5 of 60
15. For G9U 630, remove turbocharger (1) from exhaust manifold (2)
• Remove 3x nut (3), gasket 1 2
S 0012891
16. For G9U 730, remove exhaust manifold with turbocharger (1) from
cylinder head
Note: Turbocharger shown removed for clarity.
• Remove 9x nut, 9x washer (2)
• Remove gasket
Page 6 of 60
17. Remove coolant pipe (1) from coolant pump and thermostat housing
• Place collecting container below
• Remove bolt (2)
• Pull out coolant pipe
• Remove 2x O ring
• Install 2x new blanking plug
18. Remove heat shield (1) (if installed) from engine mount bracket
• Remove 2x bolt (2)
Page 7 of 60
20. Remove support bracket (if installed) from power steering pump and
and exhaust gas recirculation (EGR) valve housing
• Remove 2x bolt
Page 8 of 60
24. For G9U 730, remove guide tube (2) for oil level dipstick (1) from
engine
• Remove 2x bolt (3)
• Pull out
25. For G9U 630, remove upper section of guide tube for oil level dipstick from lower section
• Remove bolt
• Pull guide tube upwards, then release 2x clip
• Remove O ring
26. For G9U 630, remove lower section of guide tube for oil level dipstick from engine
• Remove bolt
• Withdraw lower section
• Install new blanking plug to engine
• Remove O ring
27. For G9U 730, disconnect 2x harness connector (1) from starter (2),
then move to side
• Remove 2x nut (3)
Page 10 of 60
35. Remove timing belt from engine – see operation “Timing Belt, Replace”
• G9U 630
• G9U 730
37. Remove camshaft sensor (2) from casing of high pressure pump
• Remove bolt
Important: Ensure that the casing of the high pressure pump is not
damaged when removing blanking cover.
38. Remove blanking cover (1) from casing of high pressure pump
• Prise out using suitable tool
39. Remove Positioning Pin KM-6203 (arrowed) from oil filter housing
Page 15 of 60
42. Remove guide roller (2) for timing belt from engine
• Remove bolt (1)
Page 17 of 60
45. Remove nut (1) from gear for high pressure pump
Page 18 of 60
54. Remove intermediate gear (1), shaft (2) and washer (3) from engine
• Pull out
55. If installing new intermediate gear – see operation “Intermediate Timing
Gear, Replace (All G9 Engines)” for timing gear compensation
Page 22 of 60
57. Remove secondary intermediate shaft (1) and washer (2) from engine
• Pull out
Page 23 of 60
63. Disconnect high pressure pipe (1) from high pressure pump
• Release pipe union
– Use Pipe Spanner KM-812 ; counterhold nut on high pressure
pump using suitable spanner
• Install 2x new blanking plug
64. Disconnect fuel leak-off pipe (2) from high pressure pump
• Release integral clip
• Install 2x new blanking plug
65. Disconnect fuel feed pipe (3) from high pressure pump
• Release 2x integral clip
• Install 2x new blanking plug
Install
77. Install high pressure pipe to common rail and high pressure pump; do
not tighten at this stage
• Remove 4x blanking plug
Page 31 of 60
79. Install new fuel leak-off pipe with fuel temperature sensor to 4x fuel
injector
• Remove 8x blanking plug
• Secure 4x clip to 4x fuel injector
– Push in
89. Install intermediate shaft and secondary intermediate shaft (2) with 2x
washer (1) to engine
• Ensure location pin of each intermediate shaft engages fully into
slot, then install 2x washer
• Push fit
Page 35 of 60
Important: Marking “2” on gear for high pressure pump must align with
marking “3” on timing case. This action is necessary to correctly align gear
for high pressure pump and camshaft position sensor for engine timing.
96. Install gear to high pressure pump
• Install nut (1) 90 Nm
– Ensure 2x mark (2, 3) align
97. If installing new high pressure pump gear – see operation “High
Pressure Pump Gear, Replace (All G9 Engines)” for timing gear
compensation
Page 38 of 60
98. Remove Locking Tool (1) KM-6293 from gear for high pressure pump
100. Install new gasket for timing gear cover to timing gear case
• Clean mating surfaces
101. Remove oil seal for crankshaft pulley (1) from timing gear cover
• Prise out oil seal, using suitable tool
102. Remove oil seal for secondary intermediate gear (2) from timing gear
cover
• Prise out oil seal, using suitable tool
105. Fully install oil seal for crankshaft pulley to timing gear cover
• Use Installer KM-6298
• Locate Sleeve KM-6243-3 (1) onto oil seal
• Rotate nut (2) clockwise, until oil seal fully installed into housing
Note: Stop tightening nut immediately when resistance
experienced.
Page 41 of 60
110. Install new guide roller (2) for timing belt to engine
• Install bolt (1) 30 Nm
Page 44 of 60
116. Install new timing belt to engine – see operation “Timing Belt, Replace”
• G9U 630
• G9U 730
120. Rotate engine/transmission 180°, using Engine Overh aul Stand KM-412
121. Remove oil pan from cylinder block
• Remove remaining 19x bolt
• Remove gasket
• Clean mating surface of oil pan and cylinder block
Page 48 of 60
124. Rotate engine/transmission 180°, using Engine Overh aul Stand KM-412
125. Install engine hoist to engine and transmission assembly
• Install lifting chain to 2x engine lifting eye
• Adjust engine hoist until weight of engine and transmission fully supported
126. Remove engine with transmission from Engine Overhaul Stand KM-
412
• Remove 2x Stand Adapter KM-412-29 from cylinder block
• Remove 6x bolt (1)
• Remove 8x nut, bolt
Page 50 of 60
128. For G9U 730, connect 2x harness connector (1) to starter (2)
• Secure 13 mm nut (3) 9 Nm
• Secure 8 mm nut (3) 5 Nm
130. For G9U 730, install guide tube (2) for oil level dipstick (1) to engine
• Push fit
• Install 2x bolt (3)
Page 52 of 60
131. For G9U 630, install lower section of guide tube for oil level dipstick to engine
• Install new O ring
• Remove blanking plug from engine
• Install bolt 25 Nm
132. For G9U 630, install upper section of guide tube for oil level dipstick to lower section and engine
• Remove blanking plug
• Install new O ring
• Push into lower section of guide tube to secure to 2x clip
• Install bolt 6 Nm
134. Install new pipe (1) to cylinder head and EGR valve housing
• Clean mating surfaces
• Install 2x new gasket
Page 53 of 60
• Install 4x bolt 25 Nm
135. Connect harness connector to EGR valve
• Secure integral clip
136. Install support bracket (if installed) to power steering pump and EGR
valve housing
• Install 2x bolt
138. Install heat shield (1) (if installed) to engine mount bracket
• Install 2x bolt (2)
139. Install coolant pipe (1) to coolant pump and thermostat housing
• Remove 2x blanking plug
• Clean mating surfaces
• Install 2x new O ring
– Apply suitable lubricant
• Install bolt (2)
• Push fit
Page 55 of 60
140. For G9U 730, install exhaust manifold with turbocharger to cylinder
head
Note: Turbocharger shown removed for clarity.
• Clean mating surfaces
• Install new gasket, 9x spacer, 9x new nut 30 Nm in sequence
shown
141. For G9U 730, install exhaust heat shield to exhaust manifold
• Install 3x bolt (1)
Page 56 of 60
142. For G9U 630, install turbocharger (1) to exhaust manifold (2)
• Clean mating surfaces 1 2
• Install new gasket
• Install 3x new nut (3); do not tighten at this stage
S 0012891
143. For G9U 630, install bracket (1) to turbocharger and engine
• Install 2x bolt (2); do not tighten at this stage
Page 57 of 60
2
1
S 0012890
146. Install new oil feed pipe (3) to turbocharger and engine
• Remove 4x blanking plug
• Install new O ring
• Secure pipe union 22 Nm
– Use Pipe Spanner KM-812
• Install bolt 15 Nm
• Secure bracket on oil feed pipe to turbocharger 1
– Install bolt
2 S 0016489
S 0012886
151. Install bracket (2), left side to primary catalytic converter and engine
• Install 3x bolt (1)
• Secure vacuum hose to clip on bracket
152. Install bracket (3), right side to primary catalytic converter and engine
• Install 4x bolt (4)
Page 59 of 60
153. For G9U 630, install power steering pipe assembly with fluid reservoir to engine and transmission assembly
• Install 4x bolt 21 Nm
154. For G9U 630, connect high pressure pipe (1) to power steering pump
• Remove 2x blanking plug
• Install new O ring
• Secure union 24 Nm
– Use Pipe Spanner KM-812
155. For G9U 630, secure high pressure pipe to auxiliary support bracket
• Install bolt 21 Nm
Page 60 of 60
156. Install engine and transmission to vehicle – see operation “Engine with Transmission, Remove and Install”
• G9U 630
• G9U 730
Page 1 of 36
Turbocharger, Replace
J470400
Remove
S 0012751
S 0012749
5. Release air intake duct (1) from air cleaner assembly (2)
• Release 2x clip
Page 2 of 36
S 0012752
1
1
S 0012753
7. Release harness for coolant heater assembly (if installed) from support
frame
• Release clip (2)
8. Release bracket with coolant heater assembly (1) (if installed) from
support frame
• Remove bolt (3)
Page 3 of 36
1 3
S 0012860
9. Release harness (1) for mass air flow meter from support frame (2)
• Release clip (3)
1
2
3
S 0012861
Page 4 of 36
1 2
3 S 0012862
2 S 0012714
S 0012865
S 0012870
S 0012722
S 0012872
2
3
4 S 0016919
22. Release 2x harness (if installed) for 2x ABS sensor from subframe and 2x lower arm
• Release from 6x clip
• Release from 2x bracket
23. Raise vehicle
24. Remove engine and transmission undershield from vehicle
• Remove 8x bolt
25. Release 2x brake pipe from subframe
• Release 2x clip
5
S 0012879
1 2
3
S 0012881
33. Remove subframe with steering gear and 2x lower arm from vehicle
Note: Illustration shows jack removed for clarity.
• Remove 2x bolt (1)
34. Disconnect hose assembly (1) for differential pressure sensor from front
exhaust pipe (2), then move to one side
• Counterhold adapter and release union (3)
• Install 2x new blanking plug
Page 12 of 36
2 S 0012883
2 S 0012884
S 0012885
38. Remove bracket (2), left side, from primary catalytic converter and
engine
• Remove 3x bolt (1)
• Release vacuum hose from clip on bracket
39. Remove bracket (3), right side, from primary catalytic converter and
engine
• Remove 4x bolt (4)
Page 14 of 36
S 0012873
41. Remove 2x clip from 2x harness for oxygen sensor and turbocharger temperature sensor
42. Remove primary catalytic converter (1) from turbocharger
• Remove 4x nut (2), gasket
S 0012886
5
4
3 S 0012887
2
1
S 0012890
1 2
S 0012891
1
S 0012899
Install
1
S 0012899
S 0012891
2
1
S 0012890
• Install bolt 15 Nm
2
• Secure bracket to turbocharger
– Install bolt
S 0012886
S 0012873
61. Install bracket (2), left side, to primary catalytic converter and engine
• Install 3x bolt (1)
• Secure vacuum hose to clip on bracket
62. Install bracket (3), right side, to primary catalytic converter and engine
• Install 4x bolt (4)
Page 21 of 36
63. Install 2x clip to 2x harness for oxygen sensor and turbocharger temperature sensor
64. Install front exhaust pipe to diesel particulate filter
• Clean mating surfaces
• Install new gasket
• Install 2x new nut; do not tighten at this stage
65. Secure front exhaust pipe to primary catalytic converter
• Clean mating surfaces
• Install new gasket
• Install 2x new nut; do not tighten at this stage
66. Secure 4x nut 21 Nm
Page 22 of 36
S 0012885
67. Connect hose assembly (1) for differential pressure sensor to front
exhaust pipe (2)
• Remove 2x blanking plug
• Apply suitable sealant to hose assembly
• Counterhold adapter and secure union (3) 21 Nm
Page 23 of 36
2 S 0012883
2 S 0012884
69. Install subframe with steering gear and 2x lower arm to vehicle
Note: Illustration shows jack removed for clarity.
• Apply locking compound to 2x bolt – see “Sealants, Lubricants and
Locking Compounds”
• Install 2x bolt (1) 60 Nm
Page 24 of 36
70. For vehicles with additional heater, install reaction link, left side to
chassis
• Install bolt (1); do not tighten at this stage
1 2 3 4
5
S 0012879
1 2
3
S 0012881
2
3
4 S 0016919
81. Secure 2x harness (if installed) for 2x ABS sensor to subframe and 2x lower arm
• Secure to 6x clip
• Secure to 2x bracket
S 0012872
S 0012722
S 0012870
S 0012865
2 S 0012714
Page 32 of 36
1 2
3 S 0012862
98. Secure harness (1) for mass air flow meter to support frame (2)
• Secure clip (3)
1
2
3
S 0012861
99. Secure bracket with coolant heater assembly (1) (if installed) to support
frame
• Install bolt (3)
100. Secure harness for coolant heater assembly (if installed) to support
frame
• Secure clip (2)
Page 33 of 36
1 3
S 0012860
1
1
S 0012753
102. Secure air intake duct (1) to air cleaner assembly (2)
• Secure 2x clip
Page 34 of 36
S 0012752
103. Connect harness connector (3) to mass air flow meter (1)
104. Connect hose (2) to mass air flow meter
• Secure clip
2
1
3
S 0012749
1 2
S 0012751
110. To prime turbocharger, crank engine until the oil pressure indicator lamp is extinguished then continue for two seconds
111. Install engine immobiliser/instrument panel fuse to interior fuse box
112. Install left ashtray housing to instrument panel
• Secure 4x clip
113. Bleed power steering system – see operation “Hydraulic System, Bleed”
114. Refill coolant expansion tank to maximum level
115. Start engine, and run until the oil pressure indicator lamp is extinguished
116. Stop engine
117. Check engine oil level, top up if necessary
Page 1 of 2
J459000
Remove
1. Remove cylinder head from cylinder block – see operation "Gasket, Cylinder Head, Replace”
• G9U 630
• G9U 730
2. Install cylinder head to suitable work stand
Note: 2x technician required.
3. Remove valve spring from valve
• Compress spring cap and valve spring
– Use valve spring compressor (commercially available)
• Remove split collar from valve stem
• Remove valve spring and spring cap
• Release, then remove valve spring compressor
4. Remove remaining 15x valve spring in accordance with above procedure
Install
J459015
Remove
1. Remove cylinder head from cylinder block – see operation "Gasket, Cylinder Head, Replace”
• G9U 630
• G9U 730
2. Install cylinder head to suitable work stand
Note: 2x technician required.
3. Remove valve spring from one intake valve
• Compress valve spring
– Use valve spring compressor (commercially available)
• Remove split collar from valve stem
• Remove valve spring and spring cap
• Release, then remove valve spring compressor
7. Remove Tube (1) and Installer (2) assembly from valve stem
8. Install identification label to Installer (2)
• Attach masking tape, marked INTAKE
Install
16. Remove Tube (1) and Installer (2) assembly from valve stem
17. Install remaining 7x new seal to 7x intake valve guide
Page 4 of 4
21. Replace 8x valve stem seal on 8x exhaust valve guide in accordance with procedure 8x intake valve
22. Remove cylinder head from suitable work stand
Note: 2x technician required.
23. Install cylinder head to cylinder block – see operation "Gasket, Cylinder Head, Replace”
• G9U 630
• G9U 730
J491730
Remove
S 0012716
Page 2 of 11
6. Install Positioning Pin KM-6203 (arrowed), through oil filter housing into
crankshaft
• Rotate engine clockwise, until positioning pin engages in crankshaft
to position No. 1 cylinder at top dead centre on compression stroke
Note: Top dead centre mark (1) on crankshaft pulley should be in
the vertical position.
Note: No. 1 cylinder is located at the flywheel end.
PMH
S 0017785
7. Install Engine Support KM-6210-A to vehicle – see operation “Engine Support KM-6210-A, Install and Remove”
8. Lower vehicle
9. Remove hose assembly from intercooler and turbocharger
• Release 2x clip (1)
• Remove bolt (2)
10. Remove O ring from hose assembly
Page 3 of 11
2 S 0012714
11. Release 2x fuel pipe (1) from bracket, then move to one side
• Release from 2x clip
Page 4 of 11
S 0012715
12. Remove bracket with upper engine stabiliser from engine compartment
• Remove 4x bolt (2), nut (1)
2 S 0012721
13. Remove bracket for intercooler hose assembly from upper cover for timing belt
• Remove 2x bolt
S 0012722
S 0012718
Inspect
camshaft is correct.
18. Remove Locking/Measurement Tool KM-6205 (1) from exhaust
camshaft
• Remove bolt
19. Remove Locking Tool KM-6204 (2) from intake camshaft
• Remove bolt
Install
S 0012718
S 0012722
22. Install bracket for intercooler hose assembly to upper cover for timing belt
• Install 2x bolt 8 Nm
3
5 4 S 0013084
S 0012715
2 S 0012714
S 0012717
S 0012716
30. Remove Engine Support KM-6210-A – see operation “Engine Support KM-6210-A, Install and Remove”
31. Install right splash panel
• Install 2x bolt 8 Nm , screw 6 Nm
• Secure washer hose (if installed) to 2x clip
Page 11 of 11
Valve, Grind-in